a. general maintenance instructions 1-1 b. …a.general maintenance instructions long reliable...

CHARLATTE OF AMERICA, INC. CBL200E MOBILE BELT CONVEYOR

CHAPTER 2 MAINTENANCE

TABLE OF CONTENTS CHAPTER/SECTION PAGE I. SERVICING ......................................................................... 1-1

A. General Maintenance Instructions .......................................................................................... 1-1 B. Preparation For Initial Use ....................................................................................................... 1-2 C. Maintenance Check List ........................................................................................................... 1-3 D. Preventive Maintenance Schedule .......................................................................................... 1-4

1. Daily ..................................................................................................................................... 1-4 2. Monthly ................................................................................................................................ 1-8 3. Every Three Months ........................................................................................................... 1-9 4. Yearly ................................................................................................................................. 1-10

E. Lubrication Chart .................................................................................................................... 1-11 F. Lubrication Alphabetical Table .............................................................................................. 1-14 G. Lubricants, Fluids, And Capacities ....................................................................................... 1-15

II. ADJUSTMENT INSTRUCTIONS ......................................... 2-1 A. Front Brakes .............................................................................................................................. 2-1 B. Rear Brakes ............................................................................................................................... 2-1 C. Brake Light Switch .................................................................................................................... 2-2 D. Brake Pedal ................................................................................................................................ 2-2 E. Brake Bleeding .......................................................................................................................... 2-2 F. Parking Brake ............................................................................................................................ 2-3 G. Accelerator Pedal ...................................................................................................................... 2-4 H. Seat Switch (Optional) .............................................................................................................. 2-4 I. Hydraulic Pump ......................................................................................................................... 2-4 J. Toe-In.......................................................................................................................................... 2-5 K. Conveyor Belt Tracking ............................................................................................................ 2-6

Chapter 2 Contents July, 97

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CBL200E MOBILE BELT CONVEYOR CHARLATTE OF AMERICA, INC.

CHAPTER/SECTION PAGE L. Conveyor Drive Chains............................................................................................................. 2-9 M. Conveyor Motor Brake.............................................................................................................. 2-10 N. Electronic Motor Control .......................................................................................................... 2-10

III. COMPONENT REMOVAL / INSTALLATION...................... 3-1

A. Batteries ..................................................................................................................................... 3-1 B. Tires And Wheels ...................................................................................................................... 3-3 C. Rear Brake Shoes ..................................................................................................................... 3-4

D. Front Brakes .............................................................................................................................. 3-6

E. Parking Brake Pads .................................................................................................................. 3-9 F. Master Cylinder ......................................................................................................................... 3-10

G. Brake Pedal ................................................................................................................................ 3-11

H. Accelerator Pedal ...................................................................................................................... 3-12 I. Front Axle .................................................................................................................................. 3-13 J. Rear Axle .................................................................................................................................... 3-15 K. Traction Motor ........................................................................................................................... 3-17 L. Steering Cylinder ...................................................................................................................... 3-18 M. Hydraulic Steering Valve .......................................................................................................... 3-19 N. Hydraulic Pump And Motor ...................................................................................................... 3-20 O. Hydraulic Fluid Tank ................................................................................................................. 3-21 P. Electronic Motor Control .......................................................................................................... 3-22 Q. Converter ................................................................................................................................... 3-23 R. Main SCR Panel ......................................................................................................................... 3-24 S. Conveyor Drive Assembly ....................................................................................................... 3-25 T. Conveyor Brake ......................................................................................................................... 3-26 U. Conveyor Assembly .................................................................................................................. 3-27


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CHAPTER/SECTION PAGE V. Conveyor Cargo Belt ................................................................................................................ 3-28 W. Front Conveyor Drive Roller .................................................................................................... 3-29 X. Rear Conveyor Idler Roller ....................................................................................................... 3-30 Y. Rear Conveyor Lift Cylinder .................................................................................................... 3-31 Z. Front Conveyor Lift Cylinder ................................................................................................... 3-33

IV. TROUBLE SHOOTING ....................................................... 4-1 A. General Information .................................................................................................................. 4-1 B. Hydraulic System (General) ..................................................................................................... 4-2 C. Brakes (Service) ........................................................................................................................ 4-4 D. Brake (Park brake) .................................................................................................................... 4-7 E. Hydraulic Cylinders .................................................................................................................. 4-8 F. Hydraulic Pump ......................................................................................................................... 4-9 G. Steering ...................................................................................................................................... 4-12 H. Pump Motor ............................................................................................................................... 4-13 I. Rear Drive .................................................................................................................................. 4-15 J. Rear Drive Motor ....................................................................................................................... 4-16 K. 12V Converter ............................................................................................................................ 4-18 L. Electronic Motor Control .......................................................................................................... 4-19 M. Conveyor Lift System ............................................................................................................... 4-20 N. Conveyor Belt ............................................................................................................................ 4-21 O. Conveyor Drive Motor ............................................................................................................... 4-23 P. Conveyor Brake ......................................................................................................................... 4-25 Chapter 2

Contents July, 97

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Chapter 2Section 1July, 97

CHAPTER 2MAINTENANCE

I. SERVICINGA. General Maintenance InstructionsLong reliable service and the safety of those working with this unit can only be ensured by

conscientious periodic maintenance of the machine.

Anyone performing maintenance on this machine should be trained to operate it and must be familiarwith this guide.

All electrical work must be supervised and inspected by a certified electrician.

BEFORE MAINTENANCE OR SERVICING:

1. SHUTDOWN the unit on level ground (See Shutdown Procedure).

2. Turn Master Switch to the “OFF” position. If work is to be done inside the electrical control box,batteries should be disconnected.

3. Test all controls to be sure the unit will not operate.

4. Chock all (4) wheels in both directions.

5. If maintenance is to be done with conveyor in the raised position, conveyor support props must beused.

During maintenance or servicing, if the traction motor is to be run, the unit must be jacked clear of theground and securely blocked. Both rear wheels must be free to rotate.

DO NOT perform maintenance in a congested area. This could endanger the maintenance person orothers in the vicinity. The maintenance area should be as clean as possible.

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that itbe corrected by a qualified service technician.

CLEANLINESS cannot be overemphasized as the essential ingredient of a good maintenance program.Machines should be kept as free as possible of dirt and debris which could impede performance or infiltratesystems and cause premature wear or failure.

WARNINGDO NOT MOVE ANY CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE COULD BEINJURED BY THE MACHINES MOVEMENT.

DO NOT DISCONNECT A HYDRAULIC CIRCUIT FROM A CYLINDER WHILE THERE IS A LOAD ONTHE CYLINDER.

DISCONNECT BATTERIES BEFORE WORKING INSIDE THE ELECTRICAL CONTROL BOX.

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B. Preparation For Initial Use

1. Wash down the unit and remove any foreign material from the conveyor and operator’scompartment.

2. Inspect electrical cables, conduits, hydraulic hoses, and fittings for signs of wear or damage.

3. Visually inspect the condition and readability of all warning tags, labels, lights and reflectors.Replace any found missing or damaged.

4. Make a visual inspection of the tires and rims, checking for damage and lack of proper inflation.

5. Check the entire length of the unit for signs of fluid leakage.

6. Visually inspect the batteries for proper location on the unit, level of charge, and electrolyte level.

7. Check master cylinder for proper fluid level.

8. Check foot brake pedal for a firm smooth operation that ends travel prior to contact with floor.

9. Check that the parking brake lever requires an additional amount of force to make the finalmovement to the locked position.

10. Check the hydraulic tank fluid level.

11. With the master switch in the “ON” position, check the operation of the steering wheel. Theoperation should be smooth and consistent from lock to lock and back.

12. Check the rear axle housing fluid level.

13. Check the operation of the electronic readout panel.

14. Check that the conveyor lift control levers operate properly.

15. Check the conveyor belt for proper adjustment.

16. Check operation of all conveyor controls.

17. Check the conveyor reducer fluid level.

NOTICETHE FOLLOWING LIST OF MAINTENANCE CHECKS SHOULD BE PERFORMED BY A QUALIFIEDMAINTENANCE TECHNICIAN BEFORE UNIT IS PUT INTO SERVICE.

FOR MORE DETAILED INSTRUCTIONS ON MAINTENANCE PROCEDURES SEE THE FOLLOWINGPAGES.

ALL MAINTENANCE AND REPAIRS SHOULD BE PERFORMED BY A QUALIFIED MAINTENANCETECHNICIAN.

NOTICE

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C. Maintenance Check List(For Specific Instructions See the Following Pages.

ITEM OR LOCATION INSPECT ADJUST CHANGE LUBRICATE

DailyElectrical cables, conduits, hydraulichoses, and fittings.

X

Warning tags, labels, and reflectors, andlights.

X

Tires and wheels X A/RFluid leakage XBatteries XMaster cylinder XFoot brake pedal X A/RParking brake X A/RHydraulic tank X A/RSteering XRear axle housing X A/RElectronic readout panel XConveyor controls XConveyor reducer X A/RConveyor belt X A/RConverter X

Monthly (Includes Daily Check)Batteries (Cleaning and electrolyte) X A/RWheel mounting bolts X XComplete unit X

Every Three Months(Includes Daily And Monthly Check)

Grease points X XAccelerator pedal X A/R XBrake pedal X A/R XParking brake X A/R XHinges X XBattery plug latch X XCables and wiring XElectrical contacts X A/RBrakes (Front and Rear) X A/RSteering X X

Yearly (Includes Daily, Monthly, AndThree Month Check)Electric motors X A/RFront wheel bearings X XHydraulic fluid XParking brake X A/RMotor controller XConveyor brake X A/R

A/R - Perform service as required.

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D. Preventive Maintenance Schedule

1. Daily

a. Wash down the unit and remove any foreign material from the conveyor and the operator’scompartment.

b. Inspect electrical cables, conduits, hydraulic hoses, and fittings for signs of wear or damage.

c. Visually inspect the condition and readability of all warning tags, labels, lights and reflectors.Replace any found missing or damaged.

e. Make a visual inspection of the tires and rims, checking for damage and lack of proper inflation(If inflation is needed, inflate tires to 80 PSI). Check rim surface for cracking in paint, bends, orany other obvious distortion. Check tires for cuts, abrasions, and punctures.

f. Visually inspect the batteries for proper location on the unit, level of charge (batteries should befully charged) and electrolyte level.

CAUTIONDO NOT ALLOW WATER TO ENTER THE ELECTRICAL CONTROL BOX AT ANY TIME. THE COVERSHOULD BE IN PLACE AND SECURED.

ALL MAINTENANCE AND REPAIRS SHOULD BE PERFORMED BY A QUALIFIED MAINTENANCETECHNICIAN.

NOTICE

NOTICETHE UNIT SHOULD BE MAINTAINED ACCORDING TO THE SCHEDULES IN THIS SECTION. IF THEUNIT IS INVOLVED IN OPERATIONS THAT ARE UNUSUALLY SEVERE OR THE OPERATING AREAHAS A UNIQUE CLIMATE (HOT, WET, COLD. DUSTY, ETC.) A SPECIAL SCHEDULE MAY HAVE TOBE DEVELOPED.

CAUTIONDO NOT OVERFILL THE BATTERY CELLS ; SPILLED ACID CAN CAUSE TRAY CORROSION, FRAMEGROUNDS, AND LOSS OF CAPACITY.

TO A FULLY CHARGED BATTERY ADD ONLY DISTILLED, DEMINERALIZED, OR APPROVED TAPWATER TO BRING THE LIQUID IN THE CELLS TO THE PROPER LEVEL.

SEE ALSO BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS SUPPLIED WITH BATTERYFROM YOUR BATTERY SUPPLIER FOR THE PROPER FILL LEVEL.

EXTREME WATER CONSUMPTION (MORE THAN 2 - 3 GALLONS PER WEEK) MAY INDICATE TOOMUCH CHARGING, TOO HIGH A FINISH RATE, OR A CHARGER MALFUNCTION.

NOTICE

CAUTIONCONVEYOR PROPS MUST BE USED WHEN PERFORMING MAINTENANCE PROCEDURES WITHCONVEYOR IN THE RAISED POSITION.

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g. Check the master cylinder fluid level, Figure 2-1-1. (See Fluid Specifications).

aa. Clean any dirt or debris from around the fill cap.bb. Remove the fill cap.cc. Fill the master cylinder as needed with clean brake fluid.dd. Replace the fill cap securely.

HYDRAULIC FLUID TANK AND MASTER CYLINDER LOCATIONFIGURE 2-1-1

h. Check the foot brake pedal for a firm smooth operation that ends travel prior to contact withfloor. (If adjustment is required see foot brake pedal adjustment procedure)

i. Check that the parking brake requires an additional amount of force to make the final movementto the locked position. (If adjustment is required see parking brake adjustment)

j. Check the hydraulic tank fluid level Figure 2-1-1. (See Fluid Specifications)

aa. Clean any dirt or debris from around the fill cap.bb. Remove the fill cap. With the conveyor lift cylinders completely retracted, the hydraulic

fluid level should be kept at a level that is approximately 1 inch of the top of the tank.cc. Inspect the strainer screen in the bottom of the fill cap. If the screen is cut or damaged,

replace the fill cap/strainer assembly.dd. Replace the fill cap securely.

k. Check the operation of the steering wheel.

aa. Turn the master switch to the “ON” position to energize the unit.bb. Rotate the steering wheel from left to right, the operation should be smooth and consistent

from lock to lock and back.cc. If steering is OK, turn master switch back to the “OFF” position .

NOTICETHE PARKING BRAKE SHOULD ALSO BE CHECKED FOR PROPER OPERATION BY APPLYING ITWHILE THE UNIT IS ON A SLOPE OR BRINGING THE UNIT TO A SOP FROM A SLOW SPEED.

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l. Check the oil level in the rear axle housing, Figure 2-1-2. Check for indications of leakageunder the unit and at each axle hub.

aa. Park the unit on solid level surface.bb. Clean any dirt or debris from around the level/fill plug and remove.cc. The oil should just barely flow out from the level/fill hole when full.dd. Should it be necessary to add oil, add oil slowly through the level/fill hole, just until it begins

to flow back out. Allow time for the fluid to travel throughout the axle when filling.

REAR AXLE HOUSING FILL/CHECKFIGURE 2-1-2

m. Check the operating functions of the electronic readout panel located on the operator console.

Functions:aa. Indicates battery charge level.bb. Indicates electrical system faults.cc. Records hours of operation.

Operating sequence:aa. The Hours Count will appear (950 Hr.).

NOTE: The operator does not have to wait for the Hours Count to begin operation of theunit.

bb. The Battery Discharge Indicator will appear. The BDI is the normal display duringoperation. It is displayed as a percentage of full charge. For example, a display of C.65 would indicate that 65% of the charge remains.

cc. Fault conditions override all other indications.

NOTE: Any fault condition will prevent unit operation and will be displayed on the panel inplace of all other indicators.

If a fault indication P is displayed, an incorrect start-up procedure has beendetected. Repeat start-up procedure.

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n. Check for proper operation of all conveyor control levers and switches.

aa. Rotate master switch to the “BELT” position.bb. Check for the correct operation of both front and rear conveyor lift control levers.cc. Check for the correct operation of conveyor directional switches located on the left front and

left rear of the unit.dd. Check for the correct operation of the conveyor speed switch located on the left rear of the

unit.ee. Check for the correct operation of the conveyor stop switches located at all four corners of

the conveyor.

o. Check the oil level in the conveyor reducer by locating sight glass at the rear of the reducer,Figure 2-1-3. Oil level should be kept at level of sight glass.Should it be necessary to add oil:

aa. Clean any dirt or debris from around the fill plug and remove.bb. Add oil through the fill plug hole slowly until level is at sight glass.cc. Replace fill plug.

CONVEYOR REDUCER OIL LEVELFIGURE 2-1-3

p. Visually check the conveyor belt for proper adjustment and damage. (If adjustment is required,see conveyor belt adjustment procedure)

q. Check the 12 volt electrical converter. NOTE: The only indication of a converter failure is a complete failure of the 12 volt electrics.

The lights, horn, and any other 12 volt accessories will fail to operate. Before this unitis replaced, refer to the troubleshooting section.

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2. Monthly (Includes Daily Maintenance)

a. Check the electrolyte level in all cells of both batteries. If electrolyte level is low, see batterycharging and maintenance instructions supplied with your batteries.

b. Check that all battery connections are tight and free of corrosion.

c. Clean the top of both batteries. (See battery charging and maintenance instructions suppliedwith your batteries for proper cleaning instructions.)

d. Check the wheel mounting nuts for proper torque. The nuts should be torqued to 100 Ft. Lbs.

e. Make a complete walk around visual inspection of the complete unit. Checking for signs ofdamage, fluid leakage and loose or missing parts.

CAUTIONDO NOT OVERFILL THE BATTERY CELLS ; SPILLED ACID CAN CAUSE TRAY CORROSION, FRAMEGROUNDS, AND LOSS OF CAPACITY.

TO A FULLY CHARGED BATTERY ADD ONLY DISTILLED, DEMINERALIZED, OR APPROVED TAPWATER TO BRING THE LIQUID IN THE CELLS TO THE PROPER LEVEL.

SEE ALSO BATTERY CHARGING AND MAINTENANCE INSTRUCTIONS SUPPLIED WITH BATTERYFROM YOUR BATTERY SUPPLIER FOR THE PROPER FILL LEVEL.

NOTICEEXTREME WATER CONSUMPTION (MORE THAN 2 - 3 GALLONS PER WEEK) MAY INDICATE TOOMUCH CHARGING, TOO HIGH A FINISH RATE, OR A CHARGER MALFUNCTION.

WARNINGALWAYS WEAR PROTECTIVE CLOTHING, GLOVES, AND EYEWEAR WHEN PERFORMINGMAINTENANCE ON BATTERIES.

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3. EVERY THREE MONTHS (Includes Daily And Monthly Maintenance)

a. Lubricate the unit at all points marked on the Lubrication Chart (Figure 2-1-4).

b. Check the following area for corrosion, wear, and security. Lubricate with oil or a dry type oflubricant.

aa. Accelerator pedal assembly.bb. Brake pedal assembly.cc. Entire parking brake assembly.dd. Battery cover hinges.ee. Battery plug latch. (Keep oil off the contact area of the plug).ff. Conveyor hand rail hinges and latch.

c. Check all electrical cables and wiring for signs of heating, arcing, and moisture build up.

d. Check the electrical contacts. If the tips are burned or pitted they should be replaced.

e. Visually inspect the condition and operation of the front, rear, and parking brakes. Inspect allcables and linkages for signs of wear or damage, have any potential problem repaired orreplaced by a qualified maintenance technician.

aa. Minimum front pad thickness .0625 inch (1.588 mm)bb. Minimum front rotor thickness 1.18 inch (29.96 mm)cc. Minimum rear shoe thickness 1.0625 inch (1.588 mm)dd. Maximum rear drum diameter 12.15 inch (308.61 mm)ee. Minimum park brake disc thickness .315 inch (8.00 mm)ff. Minimum park brake pad thickness .0625 inch (1.588 mm)

f. Visually inspect the condition and operation of the steering linkages by hand movement of eachcomponent.

NOTICEDARKENING OF THE CONTACT TIPS DOES NOT INDICATE BURNING; THIS DARKENING ISNORMAL. BURNING IS JUDGED BY ACTUAL LOSS OF CONTACT MATERIAL OR DROPLETS OFMOLTEN CONTACT MATERIAL BEING DISPLAYED. THE CONTACT MAY BE USED UNTIL THECONTACT MATERIAL IS ALMOST COMPLETELY WORN AWAY; HOWEVER, IT IS ADVISABLE TOREPLACE THE CONTACTS IF, IN THE OPINION OF THE MAINTENANCE TECHNICIAN, THECONTACTS WILL NOT LAST UNTIL THE NEXT REGULAR INSPECTION.

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4. YEARLY (Includes Daily, Monthly, And Every Three Months Maintenance)

a. Do a complete 3 month maintenance and service check.

b. Replace the brushes and inspect the commutator in the traction motor, conveyor drive motor,and pump motor.

c. Repack the front wheel bearings.

d. Change the hydraulic tank fluid and replace the filter.

e. Check the parking brake adjustment.

f. Check the operation of the motor controller.

g. Check the condition and operation of the conveyor brake.

NOTICETHE COMMUTATOR SHOULD BE BROWN IN COLOR, SMOOTH WITHOUT EXTENSIVE GROOVES,AND WITHOUT SEVERE BURNING ALONG THE EDGES OF THE INDIDVIDUAL BARS.

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E. Lubrication ChartSee Lubrication Diagram for Specific Locations.See Lubricant Specifications.

REF. NO. LOCATION AND DESCRIPTION

Grease Fittings (See Note 1) SeeDetail

1 Rear conveyor idler roller bearings. - 2 fittings (1 fitting each side) H2 Front conveyor drive roller bearings. - 2 fittings (1 fitting each side) G3 Conveyor drive sprocket idler shaft bearings - 2 fittings (1 fitting each bearing) G4 Rear conveyor lifting frame pins - 4 fittings (2 top pins and 2 lower pins) J5 Front conveyor lifting frame pins - 2 fittings (2 lower pins) I6 Rear conveyor lift cylinder - 2 fittings (1 rod end and 1 base end) D7 Front conveyor lift cylinder - 2 fittings (1 rod end and 1 base end)8 Drive line - 3 fittings (1 for each u-joint and 1 for slide joint) B9 Rear spring Hangers - 6 fittings (2 each side rear and 1 each side front) E

10 Steering cylinder - 1 fitting (1 rod end) F11 Steering drag links - 2 fittings (1 on each side) F12 Foot brake pedal pivot bearings - 2 fittings ( 1 fitting per bearing) A

No Grease Fittings (See Note 2)13 Front conveyor lifting frame roller track - both sides14 Conveyor hand rail pivot points15 Operator’s seat sliding tracks C16 Foot brake pedal linkage C17 Accelerator pedal linkage C18 Parking brake handle and linkage C19 Front brake caliper mounts F20 Front wheel bearings F21 Battery cover hinges22 SCR bases C

Fluid levels23 Brake master cylinder24 Hydraulic fluid tank (See Note 3)25 Rear Axle E26 Conveyor drive reducer G

NOTES:1. Pump grease into fitting until old grease can be observed coming out of component.

2. Lubricate with oil or a dry type of lubricant.

3. Hydraulic fluid specification may have to be altered due to different climates.

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LUBRICATION CHARTFIGURE 2-1-4A

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LUBRICATION CHARTFIGURE 2-1-4BPro

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F. Lubrication Alphabetical Table

Component/System Lubricant TypeFittingsPresent

Accelerator Pedal Linkage Oil or Dry Type LubricantBattery Cover Hinges Oil or Dry Type LubricantBrake Master Cylinder Dot 3 Brake Fluid Heavy DutyConveyor Drive Reducer 80W 90 Heavy DutyConveyor Drive Sprocket Idler Shaft Bearings Lithium - Based Grease XConveyor Hand Rail Pivot Points Oil or Dry Type LubricantDrive Line Lithium - Based Grease XFoot Brake Pedal Linkage Oil or Dry Type LubricantFoot Brake Pedal Pivot Bearings Lithium - Based Grease XFront Brake Caliper Mounts Silicon - Based GreaseFront Conveyor Drive Roller Bearings Lithium - Based Grease XFront Conveyor Lifting Frame Pins Lithium - Based Grease XFront Conveyor Lift Cylinder Lithium - Based Grease XFront Conveyor Lifting Frame Roller Track Lithium - Based GreaseFront Wheel Bearings Lithium - Based GreaseHydraulic Fluid Tank AW 32 (See Note)Operator’s Seat Sliding Track Lithium - Based GreaseParking Brake Handle And Linkage Oil or Dry Type LubricantRear Axle Synthetic Gear Oil W/Limited Slip AdditiveRear Conveyor Idler Roller Bearings Lithium - Based Grease XRear Conveyor Lift Cylinder Lithium - Based Grease XRear Conveyor Lifting Frame Pins Lithium - Based Grease XRear Spring Hangers Lithium - Based Grease XSCR Bases Heat Sink Silicon GreaseSteering Cylinder Lithium - Based Grease XSteering Drag Links Lithium - Based Grease X

NOTES: Hydraulic fluid specification may have to be changed due to different climates.

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G. Lubricants, Fluids, And Capacities

LOCATION TYPE SUPPLIER CAPACITY NOTES

Hydraulic Oil Tank AW 32 UNILUBE 7 Gal. 1

Conveyor Speed Reducer Spirax HP 80W 90 SHELL 21 Oz. 2

Rear Axle Housing Spirax HP 80W 90 SHELL 3.5 Qts. 2

Front Wheel Bearings Lithium EP2 NLGI #2 CERTIFIED As Required

Brake Master Cylinder Dot 3 Heavy Duty PENNZOIL As Required

Grease Fittings Lithium EP2 NLGI #2 CERTIFIED As Required 1

NOTES:

1. With conveyor lift cylinders completely retracted.

2. When filling the axle housing and conveyor speed reducer, allow enough time for lubricant to fill thevarious cavities and around component parts in each assembly. Continue adding lubricant into eachassembly until the required level is reached.

3. Pump grease into fitting until old grease can be observed coming out of component.

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II. ADJUSTMENT INSTRUCTIONS

A. Front Brakes1. The front disc brakes require no adjustments. Only disc pad and rotor thickness

measurements should be checked at three month intervals.

a. Pad thickness minimum .0625 inch (1.588 mm)

b. Rotor thickness minimum 1.18 inch (29.96 mm)

B. Rear Brakes1. The rear drum brakes are self adjusting when the unit is driven in reverse and the brakes are

applied several times sharply. Manual adjustment is required only after the brake shoes havebeen relined or replaced. Shoe and drum measurements should be checked at three monthintervals. (For Rear Brake Shoe Removal And Installation Procedure.

2. Manual adjustment procedure: (See Figure 2-2-1)

a. After replacement shoes or lining have been installed, clean all rust and dirt from the pointswhere the shoes touch the backing plate.

b. Apply a small amount of Multi-Purpose Lubricant to the points where the shoes touch thebacking plate. Be careful not to get the lubricant on the linings.

c. Check the inside diameter of the brake drum.

aa. Shoe thickness minimum .0625 inch (1.588 mm)

bb. Drum inside diameter maximum 12.15 inch (308.61 mm)

d. Install the brake drum.e. Install the tire/wheel assembly.f. While the unit is raised and securely blocked, remove the cover from the adjusting hole

located at the bottom of the brake backing plate.g. Using adjusting tool, turn the adjusting screw inside the hole to expand the brake shoes

until they drag against the drum and lock the drum.h. When the shoes have locked the drum, loosen the adjusting screw an additional 10 to 12

notches so the drum rotates freely.i. Install the adjusting hole cover on the brake backing plate.j. Perform procedure on the other rear wheel.k. Apply the brakes. If the pedal travels more than halfway to the floor, there is too much

clearance between the brake shoes and the drums. Repeat above procedure.l. After proper adjustment has been completed, lower the unit and road test to check brake

operation. Perform road test only when the brakes will apply and the unit can be safelystopped.

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REAR BRAKE SHOE MANUAL ADJUSTMENTFIGURE 2-2-1

C. Brake Light Switch1. The brake light switch is located in the rear brake line halfway between the front and rear

wheels and requires no adjustment.

D. Brake Pedal1. The brake pedal has no required adjustments.

E. Brake Bleeding1. The brake system must be free of air to operate properly. Air can enter the when parts are

disconnected for servicing or replacement, or when the fluid level in the master cylinder isallowed to get low. Air in the system will give the brake pedal a spongy feeling uponapplication.

2. Manual bleeding procedures:

a. Chock all four wheels in both directions, to prevent the unit from moving.b. Clean dirt and debris from the bleeder screw at each wheel.c. Start with the wheel farthest from the master cylinder (right rear).d. Attach a small rubber hose to the bleeder screw and place the other end in a clear

container of brake fluid.e. Fill the master cylinder with brake fluid (check often during bleeding procedure). Have an

assistant slowly pump up the brake pedal and hold pressure.f. Open the bleed screw about ¼ turn, press the brake pedal to the floor, close the bleed

screw and slowly release the pedal. Continue until no more air bubbles are forced from thecylinder on application of the brake pedal.

g. Repeat the procedure on all remaining wheel cylinders and calipers.

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F. Parking Brake1. The parking brake assembly consists of a brake disc and brake caliper installed on the drive

line and connected to the park brake handle by a series of clevises and a cable.

2. Adjustment procedures:

a. Jack rear wheels clear of the ground and securely block. Both rear wheels must be free torotate.

b. Chock each front wheel in both directions securely to prevent the unit from moving duringadjustments.

c. Remove heat shrink tubing from brake handle. (Heat shrink tubing is installed from thefactory to prevent unauthorized adjustment).

d. With parking brake handle in the raised position, turn handle clockwise until rear wheelscan be rotated freely by hand.

e. With one maintenance technician rotating rear wheels and handle in the raised position,rotate handle counter clockwise until rear wheels cannot be rotated by hand.

f. Lower handle and apply power to the unit.g. Place direction control lever in either “FORWARD” or “REVERSE” position and depress

accelerator pedal. Rear wheels should be rotating.h. Raise handle to apply parking brake. Rear wheels should stop rotating. If rear wheels

continue rotating, lower handle and rotate counter clockwise and reapply. Continue untilthe required amount of force is achieved to stop rear wheel rotation.

i. If required, additional adjustments can be made at either end of the brake cable or at thelinkage rod. (See Figure 2-2-2).

i. Remove power from the unit and place directional control lever in the “NEUTRAL” position.j. Remove all chocks and blocking devices.k. Check parking brake operation by applying it while the unit is on a slope or applying it while

the unit is traveling at a slow speed .

PARKING BRAKE ADJUSTMENTFIGURE 2-2-2

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G. Accelerator Pedal1. The accelerator pedal requires adjustment if the hydraulic pump motor remains on for over 30

seconds, with the accelerator pedal in the rest position.

2. Adjustment procedure.

a. Turn linkage rod in the desired direction until the first switch opens and removes power fromthe motor after the accelerator pedal has been released for 30 seconds.

ACCELERATOR PEDAL ADJUSTMENTFIGURE 2-2-3

H. Seat Switch (Optional)1. The seat switch is built into the bottom seat cushion and has no adjustments. If the switch is

not operating correctly, the bottom cushion or the complete seat must be replaced.

I. Hydraulic Pump1. The hydraulic pump has no external adjustments. Should steering become difficult or problems

arise, the problem can be found in one of the following places; the hydraulic pump/motor, therotary valve, the steering cylinder, or the front axle pivots.

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J. Toe-In1. The toe-in should be set to 0.0 in.

2. Toe-in should be set using the following procedure.

a. Drive the unit in a straight line for a short distance.b. Hold the steering wheel in the same position.c. Check the toe-in by taking measurements at points A-B and C-D on the brake rotor.

d. Adjust toe-in by loosening clamps and then turning tie rod until measurements E and F areequal.

TOE-IN ADJUSTMENTFIGURE 2-2-4

NOTICEBOTH MEASUREMENTS ARE TO BE TAKEN AT THE SAME DISTANCE ABOVE GROUND LEVEL. IFTAKEN AT DIFFERENT POSITIONS, ERRORS WILL RESULT DUE TO INCLINATION OF BRAKEROTOR.

WARNINGIF ADJUSTMENT OF TOE-IN IS REQUIRED, MAKE A COMPLETE INSPECTION OF ALL THESTEERING COMPONENTS.

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K. Conveyor Belt Tracking1. The following procedure is to be used as a guide for aligning the cargo belt to the center of the

front and rear rollers.

CONVEYOR ROLLER AND ADJUSTMENT LOCATIONFIGURE 2-2-5

2. Basic fundamentals of belt alignment are as follows: (Apply to both ends of the conveyor).

a. Moving the rear idler roller toward the rear on one side with the jack screw tightens that sideof the belt, causing the belt to move to the other side.

b. Moving the rear idler roller toward the front on one side with the jack screw loosens thatside of the belt, causing the belt to move to that side.

c. Moving a crowder roller end toward the large end roller will tighten that side of the belt andforce the belt to the other side of the end roller.

d. Moving a crowder roller end toward the center of the conveyor will loosen that side of thebelt and allow the belt to move to that side of the end roller.

WARNINGKEEP HANDS AND CLOTHING AWAY FROM BELT AND ROLLERS WHILE CONVEYOR IS RUNNING.

NOTICEADJUST THE FRONT CROWDER ROLLER ONLY WHEN THE CONVEYOR IS RUNNING IN THE“REVERSE” DIRECTION. ADJUST THE REAR CROWDER ROLLER ONLY WHEN THE CONVEYOR ISRUNNING IN THE “FORWARD” DIRECTION.

IT IS NECESSARY TO WORK FROM END TO END WHEN ADJUSTING BELT TRACKING ASADJUSTMENT AT ONE END WILL AFFECT THE OTHER END. WHEN TRACKING, MAKE SMALLADJUSTMENTS AND ALLOW THE BELT TO RUN AND SETTLE IN BETWEEN ADJUSTMENTS.

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3. Adjustment procedures:

a. Check the roller end bearings for failure.b. Check the front driver roller bearings for failure. Ensure that roller bearing is centered in

frame and that all fasteners are tight.c. Check the rear roller bearings for failure. Ensure that both roller bearings are centered in

frame and that all fasteners are tight.d. Raise the front of the conveyor to approximately 4 ft. high and the rear of the conveyor to

about 3 ft. 6 in. high.e. Adjust the rear idler roller at the jack screw nuts so that it is equidistant from the rear end

of the conveyor on both sides.f. Adjust the front driver roller at the jack screw nuts so that it is equidistant from the front end

of the conveyor on both sides.

ROLLER EQUIDISTANT MEASUREMENTSFIGURE 2-2-6

g. Position the front and rear crowder rollers into their adjusting slots. Move both crowderrollers equally in desired direction to achieve correct tension on cargo belt. Correct tensionis achieved when 4 to 6 inches of the belt can be rolled up at the center of the conveyor .

h. With belt running in reverse direction, observe the position of the belt at the front of theconveyor and correct as follows:

aa. To adjust belt in direction shown in Figure 2-2-7, move left side (as viewed from rear) ofthe front crowder roller toward the front driver roller until the belt tracks on center.Adjust crowder roller 1/8 inch at a time.

WARNINGSTOP THE CONVEYOR ANY TIME THE LEFT SIDE FRONT CROWDER ROLLER IS ADJUSTED.

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CROWDER ROLLER ADJUSTMENTFIGURE 2-2-7

bb. To adjust belt in opposite direction, move right side (as viewed from rear) of the frontcrowder roller toward the front driver roller until the belt tracks on center. Adjustcrowder roller 1/8 inch at a time.

cc. To adjust belt in direction shown in Figure 2-2-8, move right side (as viewed from rear)of the front crowder roller toward the front driver roller until the belt tracks on center.Adjust crowder roller 1/8 inch at a time.

dd. To adjust belt in opposite direction, move left side (as viewed from rear) of the frontcrowder roller toward the front driver roller until the belt tracks on center. Adjustcrowder roller 1/8 inch at a time.

CROWDER ROLLER ADJUSTMENTFIGURE 2-2-8

i. Continue to make adjustments until the belt runs in the center of the front roller.j. Continue to run the conveyor in reverse while adjusting the rear jack screw nuts to center

the belt on the rear idler roller.k. Repeat above steps until both ends of the belt are centered and running true, then shift belt

to “FORWARD” direction.l. Adjust the rear crowder roller to center the belt on the rear idler roller.m. When belt is running on center, reverse belt direction and observe belt alignment. If belt

alignment is satisfactory in “REVERSE” , shift belt direction back to “FORWARD”. The beltshould stay within ½ inch in both directions at both ends. If not, go back to step h andrepeat steps as often as necessary to track belt.

n. Once proper tracking and adjustments are achieved, remove power from conveyor, securelytighten all adjusting bolts, and install all covers.

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L. Conveyor Drive Chains1. Front drive chain must be adjusted before adjusting rear drive chain.

a. Raise the front of the conveyor to a height that will allow the front conveyor safety prop to beused.

b. Remove conveyor drive assembly cover.c. Loosen (do not remove) the four (4) nuts and bolts that secures the sprocket shaft bearing

blocks to the conveyor frame.d. Loosen (do not remove) the four (4) bolts that secures the reducer to the conveyor frame.e. Slide the bearing blocks in the desired direction until correct tension is applied to the chain

(correct tension is achieved when approximately ¼ inch slack is present).f. Make sure sprocket shaft and sprockets are correctly aligned with reducer sprocket and

drive roller sprocket.g. Securely tighten the four (4) nuts and bolts that secure the bearing blocks.h. Loosen the jam nuts on the two (2) reducer adjustment bolts and use adjustment bolts to

slide reducer until the correct tension is applied to the chain. (correct tension is achievedwhen approximately ¼ inch slack is present). Check for correct alignment of sprockets.

i. Tighten jam nuts on adjustment bolts and securely tighten the four (4) reducer mountingbolts.

j. Install conveyor drive assembly cover.

CONVEYOR DRIVE CHAIN ADJUSTMENTFIGURE 2-2-9

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M.Conveyor Motor Brake1. A section of Chapter 5 is dedicated to the Conveyor Motor Brake. Refer to Chapter 5 for all

adjustments, operation, and troubleshooting.

N. Electronic Motor control1. A section of Chapter 5 is dedicated to the Electronic Motor Control. Refer to Chapter 5 for all

adjustments, operation, and troubleshooting.

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Chapter 2Section 3Feb. 00


III. COMPONENT REMOVAL AND INSTALLATION

A. Batteries

1. To remove the battery:

a. Disconnect the electrical plug connecting the battery to the unit.b. Attach a hoist or other lifting device to the battery. (Lifting device should be capable of

lifting a minimum of 4,000 lbs.). A lifting bar for this purpose is the preferred method.c. Lift the battery high enough to clear the unit.d. Place the battery in a predetermined location.

WARNINGBATTERIES CONTAIN STRONG SULFURIC ACID THAT COULD CAUSE SEVERE BURNS IF SPILLEDOR SPLASHED ON BODY PARTS OR IN THE EYES. PROTECTIVE CLOTHING, GLOVES, ANDEYEWARE MUST BE WORN WHEN HANDLING AND WORKING ON BATTERIES.

NOTE: IF SULFURIC ACID IS SPLASHED OR SPILLED ON BODY PARTS OR EYES, WASH ORFLUSH COMPLETE AREA WITH COLD WATER FOR AT LEAST 10 MINUTES AND SEEKMEDICAL ATTENTION IF BURNING OR IRRITATION PERSISTS. ANY ACID SPILLED ORSPLASHED TO THE FACE OR EYES SHOULD BE FLUSHED AT ONCE WITH COLD WATEROR EYE WASH, AND THE VICTIM SHOULD SEEK MEDICAL ATTENTION.

DUE TO THE EXTREME WEIGHT OF LEAD ACID BATTERIES, ALWAYS KEEP BODY PARTS FROMUNDER BATTERY.

BATTERIES PRODUCE EXPLOSIVE GASES THAT COULD BE IGNITED CAUSING BURNS OREXPLOSIONS. BATTERIES SHOULD BE WELL VENTED AND NOT EXPOSED TO OPEN FLAME,WELDING, SPARKS, OR ELECTRICAL ARCS.

WARNINGBATTERIES THAT HAVE BEEN REMOVED FROM A UNIT AND NOT IN USE SHOULD BE STOREDAWAY FROM HIGH TRAFFIC AREAS AND IN A WELL VENTED LOCATION.

WARNINGBATTERIES ARE EQUIPPED WITH PLASTIC STRAP COVERS FOR SHORT CIRCUIT PROTECTION.DURING MAINTENANCE PROCEDURES ON BATTERIES, DO NOT ALLOW TOOLS OR SHARP METALOBJECTS TO FALL ON THESE COVERS. THIS TYPE OF ACCIDENT COULD CAUSE BREAKAGE ORPUNCTURE OF COVERS AND LEAD TO A SHORT CIRCUIT OF BATTERY.

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2. To replace the battery:

a. Make sure that the battery well and surrounding area is clear.

b. Attach a hoist or other lifting device to the battery. (Lifting device should be capable oflifting a minimum of 4,000 lbs.). A lifting bar for this purpose is the preferred method.

c. Lift the battery high enough to clear the unit and rotate to the proper alignment over thecompartment and well.

d. Make sure no cables are under any part of the battery.e. Lower the battery into the unit, keeping hands and body parts clear of battery.f. Connect the electrical plug connecting the battery to the unit.

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B. Tires And wheels1. The tires on this unit are pneumatic and use one piece rims. Never strike these rims with a

hammer or other device that may cause damage. Only properly trained maintenancetechnicians with the correct tire mounting equipment should mount or disassemble these tiresand rims.

a. To remove the tire:

aa. Chock wheels that are not to be removed in both directions to prevent the unit frommoving and apply parking brake.

bb. Loosen the lug nuts approximately ¼ turn while the unit is on the ground.cc. Jack the unit up until the tire/wheel is clear of the ground and insert a blocking device

under the frame that will support the weight of the unit.dd. Remove the lug nuts.ee. Remove the tire/wheel assembly.

b. To dismount the pneumatic tire:

aa. Remove the valve core to deflate the tire. (Make sure tire is completely deflated).bb. Remove the tire from the rim only with a tire mounting and dismounting machine, as

found at a local tire dealer.

c. To mount the pneumatic tire:

aa. Clean all dirt and debris from rim and inspect for signs of any damage.bb. Replace tubeless valve stem.cc. Inspect the tire for any damage and clean all dirt and debris from bead and inside tire.dd. Lubricate tire bead prior to mounting.

ee. Install the tire on the rim only with a tire mounting and dismounting machine, as foundat a local tire dealer.

ff. Inflate tire to pressure indicated:

Front 80 PSI (5.44 Bar)Rear 80 PSI (5.44 Bar)

gg. Install tire/wheel on unit and securely tighten lug nuts to 100 ft. lbs.hh. Remove blocking device and jack from under unit and retighten lug nuts .

WARNINGDO NOT USE PRY BARS, HAMMERS, OR ANY OTHER SIMILAR DEVICES TO DISMOUNT THESETIRES FROM THE ONE PIECE RIMS. RIM OR TIRE DAMAGE COULD OCCUR.

NOTICEWHEN LUBRICATING TIRE BEAD, ALWAYS USE TIRE MOUNTING LUBRICANTS SUCH AS MICHELINTIGRE GREASE OR MURPHY’S TIRE MOUNTING COMPOUND.

WARNINGPROPER TIRE MOUNTING IS IMPORTANT. FAILURE TO FOLLOW SPECIFIED MOUNTINGPROCEDURES CAN CAUSE SEVERE PERSONAL INJURY AND TIRE DESTRUCTION.Pro

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C. Rear Brake Shoes1. Rear brake shoe removal procedure:

a. Chock each front wheel in both directions.b. Raise and properly support the rear of the unit.c. Remove the rear tire/wheel assembly. (See tire/wheel removal procedure).d. Loosen the rear brake shoe adjustment screw.e. Remove the rear axle shaft retaining nuts and washers.f. Pull out axle shaft. Replace gasket located between axle shaft flange and hub with a new

one at time of assembly.g. Remove the wheel bearing locknut, lockwasher, and adjusting nut.h. Remove the hub and drum from the axle. Thoroughly inspect the drum for damage, look for

cracking, severe grooving, and make sure drum inside diameter is round. If no severedamage is found, the drum can be repaired (turned) if enough material is present.

Maximum interior turned diameter 12.15 in. (308.61 mm)

i. Remove the adjusting cable assembly from the anchor pin, cable guide, and adjusting lever.j. Remove the brake shoe retracting springs.k. Remove the brake shoe hold-down spring from each shoe.l. Remove the brake shoes and adjusting screw assembly.m. Disassemble the adjusting screw assembly.n. Inspect the wheel cylinder for leaks or cracking. If damage is present, repair or replace

wheel cylinder.

REAR BRAKE SHOESFIGURE 2-3-1

NOTE:PARKING BRAKE COMPONENTS NOTUSED ON UNITS EQUIPPED WITH DRIVELINE PARKING BRAKE.

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2. Rear brake shoe installation procedure:

a. Clean the ledge pads on the backing plate. (Sand lightly to bare metal).b. Apply Multi-Purpose Lubricant to the retracting and hold-down spring contacts on the brake

shoes and backing plate.c. Clean and apply Multi-Purpose Lubricant to the threads and socket end of the adjusting

screw.d. Install the upper retracting spring on the primary and secondary shoes and position the

shoe assembly on the backing plate with the wheel cylinder push rods in the shoe slots.e. Install brake shoe hold-down springs.

f. Install the brake shoe adjustment screw assembly (with the slot in the head of the adjustingscrew toward the primary shoe), lower retracting spring, adjusting lever spring, andadjusting lever assembly.

g. Connect the adjusting cable to the adjusting lever.h. Position the cable in the cable guide and install the cable anchor fitting on the anchor pin.j. Install hub and drum on axle.k. Install wheel bearing locknut, lockwasher, and adjusting nut.l. Install axle shaft and new gasket with axle shaft retaining nuts and washers (tighten

securely).m. Install tire /wheel assembly. (See Tire/Wheel Installation procedure).n. Perform Manual Adjustment Procedure).o. Lower the unit to the ground.

WARNINGINSPECT ALL REPLACEMENT PARTS AND SHOES TO ASSURE GOOD CONDITION AND PARTSCOMPATIBILITY.

WARNINGALWAYS INSTALL THE ADJUSTING SCREW ASSEMBLIES IN THE SAME LOCATIONS FROM WHICHTHEY WERE REMOVED. INTERCHANGING THE BRAKE SHOE ADJUSTING SCREW ASSEMBLIESFROM ONE SIDE TO THE OTHER WILL CAUSE THE BRAKE SHOES TO RETRACT RATHER THANEXPAND EACH TIME THE AUTOMATIC ADJUSTING MECHANISM IS OPERATED.

WARNINGAFTER COMPLETION OF ANY WORK PERFORMED ON THE BRAKING SYSTEM, THE BRAKESSHOULD BE BLED, THE FLUID LEVEL IN THE MASTER CYLINDER CHECKED, AND A TEST DRIVEMADE.

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D. Front Brakes

1. Brake pad removal procedure:

a. Chock each rear wheel in both directions.b. Raise and properly support the front of the unit.c. Remove the front tire/wheel assembly. (See Tire/Wheel Removal Procedure).d. Remove 2/3 of the brake from the master cylinder.e. Position C-clamp as shown in Figure 2-3-2 and tighten until piston bottoms in bore.

FRONT BRAKE PAD REMOVALFIGURE 2-3-2

f. Remove C-clamp.g. Remove brake hose inlet fitting bolt if caliper is to be completely removed.h. Remove allen head mounting bolts and inspect for corrosion. If corrosion is found, use new

bolts when installing caliper.

WARNINGINSPECT THE CALIPERS, ROTORS, LINES, AND NEW PADS TO ASSURE GOOD CONDITION ANDPARTS COMPATIBILITY.

NOTICEWHEN REMOVING THE CALIPER, IT MAY BE NECESSARY TO LOOSEN THE BLEED SCREW ANDSPREAD THE PADS TO PERMIT TRAVEL PAST ANY RUST OR GROOVING ON THE OUTSIDE EDGEOF THE ROTOR. THIS PROCEDURE WILL CAUSE SOME FLUID LOSS THAT MAY REQUIRE FLUIDADDITION TO THE MASTER CYLINDER AFTER BRAKE WORK HAS BEEN COMPLETED.

WARNINGBRAKE PADS MAY CONTAIN ASBESTOS. TAKE ALL NECESSARY PRECAUTIONS TO ENSURETHAT DUST FROM BRAKE PADS IS NOT INHALED.

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i. If only pads are being replaced, remove caliper from rotor and suspend with a wire hookfrom machine chassis .

j. Remove brake pads from caliper.k. Remove sleeves and bushings from groves in mounting bolt holes and inspect for damage

or corrosion. If damage or corrosion is found, replace sleeves and bushings at assembly.l. Examine piston area for fluid leaks around boot area. Check dust boot for damage that

may affect its ability to seal the piston bore. If damage or leaks are present, the calipershould be replaced or repaired.

m. If no caliper damage is found, clean the entire caliper, including the mounting ears and theoutside surface of the dust boot.

n. Slowly and carefully push piston fully back into its bore (if the piston was not fullydepressed earlier).

FRONT BRAKE CALIPERFIGURE 2-3-3

2. Brake pad only installation procedure:

a. Check the hub bearings for play.b. Check the rotor for run out.c. Check both sides of rotor for scoring or rough finish. During normal use, a slight ridge of

rust may form on the edge of the disc. This ridge can be removed with sandpaper.d. Check the rotor thickness.

Minimum thickness 1.18 in. (29.96 mm)

e. Install bushings and sleeves in mounting bolt holes.f. Install retainer spring on inboard pad and install in caliper.f. Install outboard pad with wear sensor to the rear of caliper.

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g. Tighten brake pads to caliper by squeezing brake shoe ears down on caliper with channel-lock pliers, Figure 2-3-4.

h. Place caliper in mounting bracket and install mounting bolts (tighten securely).

FRONT BRAKE PAD INSTALLATIONFIGURE 2-3-4

I. Install brake hose inlet fitting and tighten securely, if complete caliper was removed.j. Install tire/wheel assembly and lower the unit to the ground. (See Tire/Wheel Installation

Procedure).

k. Check fluid level in master cylinder and bleed brakes, (See Brake Bleeding Procedure)

WARNINGAFTER COMPLETION OF ANY WORK PERFORMED ON THE BRAKING SYSTEM, THE BRAKESSHOULD BE BLED, THE FLUID LEVEL IN THE MASTER CYLINDER CHECKED, AND A TEST DRIVEMADE.

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E. Parking Brake Pads1. Parking brake pad removal procedure:

a. Chock front and rear wheels in both directions to prevent unit from moving.b. Hydraulically raise the front and rear of the conveyor high enough to allow use of both the

conveyor support props.c. Unbolt and remove the drive assembly cover.d. Check to be sure that the parking brake lever is in the lowered position.e. Remove cotter pin and pin from parking brake pivot arm clevis and swing clevis clear of

parking brake assembly.f. Loosen and remove the two (2) mounting nuts and bolts that secures the brake to the brake

mount.g. Remove brake assembly from unit.f. Loosen and remove the two (2) nuts and bolts from the brake assembly. (Do not lose

spacers and Springs when the bolts are removed from the assembly).g. Remove old pads from brake assembly.

2. Parking brake pad installation procedure:

a. Installation of the parking brake pads is accomplished by reversing the order of the abovesteps.

b. Upon completion of the parking brake pad installation procedure, adjustment of the parkingbrake will be required.

PARKING BRAKE PADSFIGURE 2-3-5

WARNINGWHEN PERFORMING MAINTENANCE PROCEDURES WITH THE CONVEYOR IN THE RAISEDPOSITION, ALWAYS USE CONVEYOR SUPPORT PROPS.

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F. Master Cylinder1. To remove the master cylinder:

a. Wipe clean and disconnect the two (2) brake lines from the master cylinder.b. Cap and plug disconnected brake lines.c. Remove mounting bolts and pull the master cylinder from it mounting location.

2. To install the master cylinder:

a. Thoroughly clean master cylinder mounting location.b. Place master cylinder in proper location and install mounting bolts. (Tighten mounting bolts

securely).c. Connect both brake lines to master cylinder and tighten securely.d. Bleed air from brake system. (See Brake Bleeding Procedure).

MASTER CYLINDERFIGURE 2-3-6

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G. Brake Pedal1. Brake pedal removal procedure:

a. Remove the cover from under the dash panel to allow access to brake pedal components.b. Remove the cotter key and pin from the clevis connected to the brake pedal weldment,c. Remove the four (4) mounting nuts and bolts from both bearings.d. After mounting nuts and bolts have been removed, lower pedal weldment with bearings from

under dash panel.

2. Brake pedal installation procedure:

a. Installation of the brake pedal is accomplished by reversing the order of the above steps.

BRAKE PEDALFIGURE 2-3-7

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H. Accelerator Pedal Assembly1. Accelerator pedal removal procedure:

a. Remove the cover from under the dash panel to allow access to accelerator pedalcomponents.

b. Remove the cotter key and pin from the clevis connected to the accelerator pedalweldment,

c. Remove the nut from the pivot bolt.d. Pull the pivot bolt from the mounting bracket and accelerator pedal weldment and remove

the pedal.

2. Accelerator pedal installation procedure:

a. Installation of the accelerator pedal is accomplished by reversing the order of the abovesteps.

ACCELERATOR PEDALFIGURE 2-3-8

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H. Accelerator Pedal/Switch (Continued)When replacing the accelerator switch module, follow the following chart to ensure proper wiring.

FOR 610 CONTROLLERS ONLY

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I. Front Axle1. Front axle removal procedure: (See Figure 2-3-9)

a. Chock rear wheels in both directions to prevent unit from moving.b. Jack the front frame of the unit up and place jack stands or approved blocking devices

rearward of the front axle.c. Remove tire/wheel assemblies from front axle.

d. Wipe clean and disconnect hydraulic brake lines from front disc brake assemblies.e. Cap and plug disconnected brake line.f. Wipe clean and disconnect hydraulic lines from steering cylinder.g. Cap and plug hydraulic lines and ports.

h. Use a transmission jack to support the front axle.i. Remove the two (2) center bolts and rubber isolators that attach the front axle to the frame.j. Lower the transmission jack and roll axle out toward the front of the unit.

2. Front axle installation procedure:

a. Installation of the front axle is accomplished by reversing the order of the above steps athrough j.

b. Upon completion of front axle installation, bleed air from brake system.

WARNINGWHEN THE UNIT IS RAISED AND BLOCKED, ALWAYS USE APPROVED BLOCKING DEVICES THATWILL SUPPORT THE UNITS WEIGHT.

CAUTIONWIPE CONNECTIONS CLEAN PRIOR TO OPENING BRAKE AND HYDRAULIC SYSTEM.

CAP OR PLUG ALL OPEN PORTS.

NOTICEUSE BACK-UP WRENCHES ON ALL MATING PARTS.

WARNINGDO NOT LIFT UNIT FRAME FROM JACK STANDS WHEN SUPPORTING FRONT AXLE WITHTRANSMISSION JACK.

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FRONT AXLEFIGURE 2-3-9

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J. Rear Axle1. Rear axle removal procedure: (See Figure 2-3-10)

a. Chock front wheels in both directions to prevent unit from moving.b. Jack the rear frame of the unit up and place jack stands or approved blocking devices

forward of the rear axle.c. Remove tire/wheel assemblies from rear axle.

d. Wipe clean and disconnect hydraulic brake line mounted on rear axle.e. Cap and plug disconnected brake line.f. Disconnect drive shaft at rear axle universal and secure u- joint bearing caps to u-joint with

tape or similar material.

g. Use a transmission jack to support the rear axle.h. Remove the four (4) u-bolts that attach the rear axle to the leaf springs.i. Lower the transmission jack and roll axle out toward the rear of the unit.

2. Rear axle installation procedure:

a. Installation of the rear axle is accomplished by reversing the order of the above steps athrough i.

b. Upon completion of rear axle installation, bleed air from brake system.

WARNINGWHEN THE UNIT IS RAISED AND BLOCKED, ALWAYS USE APPROVED BLOCKING DEVICES THATWILL SUPPORT THE UNITS WEIGHT.

CAUTIONWIPE CONNECTION CLEAN PRIOR TO OPENING BRAKE SYSTEM.

CAP OR PLUG ALL OPEN PORTS.

NOTICEUSE BACK-UP WRENCHES ON ALL MATING PARTS.

WARNINGDO NOT LIFT UNIT FRAME FROM JACK STANDS WHEN SUPPORTING REAR AXLE WITHTRANSMISSION JACK.

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REAR AXLEFIGURE 2-3-10

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K. Traction Motor1. Traction Motor removal procedure:

a. Raise both the front and rear of the conveyor to allow use of the conveyor support props.b. Disconnect the battery plugs, to remove power from the unit.c. Unbolt and remove the drive assembly cover.d. Remove and tag motor leads from the traction motor.e. Remove the four (4) bolts that connect the drive shaft to the park brake disc.f. Disconnect the parking brake cable from the brake mount.g. Locate a sling under the center of the motor and attach it to a crane or engine lift.h. Remove the four (4) motor mounting bolts and nuts.i. Using crane or hoist, raise motor high enough to allow the motor to be removed from the

unit.j. After motor is completely removed from the unit, remove the parking brake mount and

associated hardware.

2. Traction motor installation procedure:

a. Installation of the traction motor is accomplished by reversing the order of the above steps.b. Upon completion of the traction motor installation procedure, adjustment of the parking

brake may be required. (See page 2-3 for procedure).

TRACTION MOTORFIGURE 2-3-11

WARNINGWHEN PERFORMING MAINTENANCE PROCEDURES WITH THE CONVEYOR IN THE RAISEDPOSITION, ALWAYS USE CONVEYOR SUPPORT PROPS.

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L. Steering Cylinder1. Steering cylinder removal procedure:

a. Chock both rear wheels in each direction.b. Raise the front of the conveyor to allow use of the conveyor support prop.c. Raise and properly support the front end of the unit.d. Wipe clean and disconnect the two hydraulic hoses from the steering cylinder. Tag and

mark hoses after disconnecting.e. Take measure A as shown in Figure 2-3-12 on cylinder rod end to allow replacement

cylinder to be installed to the same position as the removed cylinder.f. Remove nut and pin from base end of cylinder.g. Loosen bolts in drag link clevis to allow rod end of cylinder to be disconnected from drag

link assembly.h. Remove cylinder from unit.i. Inspect cylinder pin and drag link for wear or damage.

2. Steering cylinder installation procedure:

a. Installation of the steering cylinder is accomplished by reversing the order of the abovesteps.

STEERING CYLINDERFIGURE 2-3-12

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M.Hydraulic Steering Valve1. The steering valve is located below the steering column.

2. Steering valve removal procedure:

a. Wipe clean and disconnect hydraulic lines connected to steering valve. (Tag and plughydraulic lines after disconnecting).

b. Remove the steering wheel cap to gain access to the steering wheel lock nut.c. Remove lock nut from steering wheel and lift steering wheel from steering column.d. While holding the assembly temporarily in place under the dash panel, remove the four (4)

nuts and lockwashers that are holding the steering column to the dash panel.

e. Slowly lower steering valve and column from under the dash panel, being careful not todamage and electrical wiring located under dash panel.

2. Steering valve installation procedure:

a. Installation of the steering valve is accomplished by reversing the order of the above steps.

HYDRAULIC STEERING VALVEFIGURE 2-3-13

NOTICETHE STEERING VALVE AND COLUMN ARE CONNECTED TO THE DASH PANEL WITH THE SAMENUTS AND LOCKWASHERS.

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N. Hydraulic Pump And Motor1. Hydraulic pump and motor removal procedure:

a. Disconnect the battery plugs, to remove power from the unit.b. Unbolt and remove the pump drive assembly cover.c. Remove and tag electrical pump motor leads.d. Wipe clean and disconnect hydraulic hoses from the pump. Tag and cap hoses after

removal.e. Loosen and remove the four (4) nuts and lockwashers the holds the mounting bracket in

place.f. While holding pump drive assembly in place, remove mounting bracket and rubber strip.g. Remove motor and pump from unit as a complete assembly.

2. Hydraulic pump and motor installation procedure:

a. Installation of the hydraulic pump and motor is accomplished by reversing the order of theabove steps.

b. After installation is completed, air must be bled from hydraulic system.

HYDRAULIC PUMP AND MOTORFIGURE 2-3-14

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O. Hydraulic Fluid Tank1. Hydraulic fluid tank removal procedure:

a. Hydraulically raise the front of the conveyor to allow use of the conveyor support prop.b. Remove the drain plug from the bottom of the fluid tank to allow hydraulic fluid to drain.c. Wipe clean and disconnect the suction and return lines to the tank. Tag and cap hoses

after disconnecting.d. Remove the four (4) bolts that secures the tank and lift tank from unit.e. Unscrew and remove strainer from tank.f. Remove the fill cap assembly.

2. Hydraulic fluid tank installation procedure:

a. Flush and clean inside of tank thoroughly.b. Inspect the strainer for damage. If the strainer is not torn or damaged, it can be cleaned

using kerosene and a soft brush and dried thoroughly. If the strainer is damaged, it mustbe replaced.

c. Insert the strainer in tank and tighten securely.d. Inspect the fill cap assembly strainer for damage. If the strainer is not torn or damaged, it

can be cleaned using kerosene and a soft brush and dried thoroughly. If the strainer isdamaged, it must be replaced.

e. Install the fill cap assembly in top of tank.f. Install drain plug in bottom of tank.g. Align tank over chassis frame and install the four (4) bolts and lockwashers that secures

tank and tighten securely.h. Wipe clean and reconnect suction and return line to tank.i. Fill tank to the proper level. (See Fluid Specifications).

HYDRAULIC FLUID TANKFIGURE 2-3-15

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P. Electronic Motor Control1. Electronic motor control removal procedure:

a. Disconnect batteries and remove all metallic jewelry.b. Remove cover from electrical control box.c. Disconnect and tag all wiring to electronic motor control.e. Remove the four (4) mounting bolts that hold the electronic motor control in place.f. Remove the electronic motor control from the electrical control box, be careful not to

damage any electrical wiring.

3. Electronic motor control installation procedure:

a. Electronic motor control installation is accomplished by reversing the order of the abovesteps.

ELECTRONIC MOTOR CONTROLFIGURE 2-3-16

WARNINGDISCONNECT BATTERIES AND REMOVE ALL METALLIC JEWELRY BEFORE WORKING INSIDE THEELECTRICAL CONTROL BOX TO PREVENT ELECTRICAL SHOCK.

NOTICESEE CHAPTER 5 FOR MORE DETAILED INFORMATION ON THE ELECTRONIC MOTOR CONTROL.

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Q. Converter1. The converter is located in the electrical control box directly behind the operator’s seat.

2. Converter removal procedure:

a. Disconnect batteries and remove all metallic jewelry.b. Remove cover from electrical control box.c. Disconnect and tag all wiring to converter.e. Remove the four (4) mounting bolts that hold the converter in place.f. Remove the converter from the electrical control box, be careful not to damage any

electrical wiring.

3. Converter installation procedure:

a. Converter installation is accomplished by reversing the order of the above steps.

CONVERTERFIGURE 2-3-17


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R. Main SCR Panel1. SCR panel removal procedure:

a. Disconnect batteries and remove all metallic jewelry.b. Remove cover from electrical control box located behind operator’s seat.c. The SCR panel is a self contained unit that can be changed out as one complete

assembly.

aa. Disconnect and tag all associated wiring connected to the panel.bb. Remove the three (3) bolts that secure the panel to the aluminum heat sink below it.cc. Lift panel clear of electrical control box.

d. Individual components can also be removed and replaced from the SCR panel. To performthis procedure refer to the SCR panel dedicated section in Chapter 5.

2. SCR panel installation procedure:

a. Installation of the SCR panel is accomplished by reversing the order of the above steps athrough d.

MAIN SCR PANELFIGURE 2-3-18


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S. Conveyor Drive Assembly1. Conveyor drive assembly removal procedure:

a. Raise conveyor hydraulically, high enough to allow use of the front conveyor prop.b. Disconnect the batteries to remove power from the machine.c. Remove conveyor drive cover located under the front section of the conveyor assembly.d. Remove drive chain cover from right front side of conveyor.e. Remove drive motor and brake assembly. (See Conveyor Brake)f. Loosen the four (4) reducer mounting bolts and reduce tension on rear drive chain with the

two (2) reducer adjustment bolts.g. Remove rear drive chain from sprockets.h. Remove the four (4) bolts, nuts, and washers from the bearing blocks and remove front drive

chain.i. Bearing blocks, shaft and both shaft sprockets can be removed as a complete assembly.j. Inspect sprockets, keys, and chains for wear or damage and replace if required.

2. Conveyor brake installation procedure:

a. Installation if the conveyor drive assembly is accomplished by reversing the order of theabove steps.

CONVEYOR DRIVE ASSEMBLYFIGURE 2-3-19

WARNINGALWAYS USE SAFETY PROPS WHEN PERFORMING MAINTENANCE PROCEDURES WITH THECONVEYOR IN THE RAISED POSITION.

WARNINGDISCONNECT BATTERIES BEFORE DISCONNECTING BRAKE AND MOTOR WIRING TO PREVENTELECTRICAL SHOCK.

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T. Conveyor Brake1. Conveyor brake removal procedure:

a. Raise conveyor hydraulically, high enough to allow use of the front conveyor prop.b. Disconnect the batteries to remove power from the machine.c. Remove conveyor drive cover located under the front section of the conveyor assembly.d. Disconnect and tag all associated wiring going to the conveyor motor and brake.e. Loosen (DO NOT REMOVE) the four (4) brake mounting bolts.f. Secure brake and motor assembly to the conveyor to prevent it from falling once mounting

bolts are removed.g. Remove brake mounting bolts.h. Complete brake and motor assembly is now ready to be removed from the machine.i. Remove the four (4) motor mounting bolts and separate motor from brake.

2. Conveyor brake installation procedure:

a. Installation if the conveyor brake is accomplished by reversing the order of the above steps.

CONVEYOR BRAKEFIGURE 2-3-20

WARNINGALWAYS USE SAFETY PROPS WHEN PERFORMING MAINTENANCE PROCEDURES WITH THECONVEYOR IN THE RAISED POSITION.

WARNINGDISCONNECT BATTERIES BEFORE DISCONNECTING BRAKE AND MOTOR WIRING TO PREVENTELECTRICAL SHOCK.

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U. Conveyor Assembly1. Conveyor removal procedure:

a. Raise conveyor hydraulically, both front and rear, high enough to allow use of the conveyorsafety props.

b. Block up both front and rear of conveyor between unit frame and conveyor cross member, orsupport with sling and hoist with a minimum capacity of 2,000 pounds.

c. Disconnect electrical plug connecting batteries to the unit.d. Disconnect and tag electrical wiring and cables at the conveyor drive motor and brake

assembly.e. Remove both pivot pins and nuts from the top of the rear conveyor lifting frame.f. Remove both pivot pin rollers and nuts from the top of the front conveyor lifting frame.g. Using proper lifting gear of 2,000 pound minimum capacity, lift conveyor assembly from

pivot attaching points.

2. Conveyor installation procedure:

a. Installation of the conveyor assembly is accomplished by reversing the order of the abovesteps.

WARNINGALWAYS USE SAFETY PROPS WHEN PERFORMING MAINTENANCE PROCEDURES UNDERCONVEYOR.

WARNINGHOIST AND SLING CAPACITY SHALL BE 2,000 POUNDS MINIMUM.

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V. Conveyor Cargo Belt1. Conveyor belt removal procedure:

a. Raise conveyor hydraulically, both front and rear, high enough to allow use of the conveyorsafety props.

b. Loosen (Do not remove) the adjustment bolts of both the front and rear crowder adjustmentrollers to remove tension from cargo belt.

c. Loosen the adjustment nuts (both sides) on the rear conveyor idler roller to remove tensionfrom cargo belt.

d. Store conveyor props and completely lower conveyor assembly.e. Remove alligator lacing from belt.f. Remove old belt from conveyor assembly.

2. Conveyor belt installation procedure:

a. Raise conveyor hydraulically, both front and rear, high enough to allow proper alignment ofcargo belt through conveyor rollers. (See Figure 2-3-21 for proper alignment).

b. Connect cargo belt at both end points with alligator lacing.c. Adjust tension and belt tracking.

CONVEYOR CARGO BELT ALIGNMENTFIGURE 2-3-21

WARNINGALWAYS USE SAFETY PROPS WHEN PERFORMING MAINTENANCE PROCEDURES UNDERCONVEYOR.

WARNINGALWAYS USE SAFETY PROPS OR PROPERLY BLOCK UP CONVEYOR WHEN PERFORMINGMAINTENANCE PROCEDURES UNDER CONVEYOR.

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W.Front Conveyor Drive Roller1. Front conveyor drive roller removal procedure:

a. Remove cargo belt from conveyor assembly. (See cargo belt removal procedure

b. Unbolt and remove both outside access covers and bumper blocks from the front of theconveyor.

c. Apply power to the conveyor and drive belt slowly, until front drive chain master link isvisible from the outside of the conveyor.

d. Stop belt and disconnect power from the unit by unplugging the battery connectors.e. Slacken chain. (See conveyor drive chain adjustment for complete slackening procedure,

f. Remove chain master link to remove drive chain.g. Loosen allen head set screw located to the inside of sprocket and pull sprocket from roller

shaft.h. Remove the four (4) bolts that secures the right side bearing to the mounting plate.i. Unbolt and remove the mounting plate from the conveyor frame.j. Remove the outside nut from the roller adjustment rod located on the front left side of the

conveyor and loosen the inside nut to allow for free movement of roller.k. Remove drive roller from conveyor frame with both shaft bearings.l. Loosen allen head set screw located to the inside of each bearing and pull bearings from

roller shaft.

2. Front conveyor drive roller installation procedure:

a. Installation of the conveyor drive roller is accomplished by reversing the order of the abovesteps.

FRONT CONVEYOR DRIVE ROLLERFIGURE 2-3-22


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X. Rear Conveyor Idler Roller1. Rear conveyor idler roller removal procedure:

a. Remove cargo belt from conveyor assembly. (See cargo belt removal procedure)

b. Unbolt and remove both outside access covers and bumper blocks from the rear of theconveyor.

c. Remove the outside nut from both of the roller adjustment rods accessed from the outsideof the conveyor and loosen the inside nut to allow for free movement of roller.

d. Remove roller from conveyor frame with both shaft bearings.e. Loosen allen head set screw located to the inside of each bearing and pull bearings from

roller shaft.

2. Rear conveyor idler roller installation procedure:

a. Installation of the rear conveyor idler roller is accomplished by reversing the order of theabove steps.

REAR CONVEYOR IDLER ROLLERFIGURE 2-3-23


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Y. Rear Conveyor Lift Cylinder1. Rear conveyor lift cylinder removal procedure: (See Figure 2-3-24)

a. Raise rear of belt conveyor either hydraulically or with a hoist and sling (while holding rearlift cylinder control valve open).

b. Lower rear conveyor support prop to support conveyor weight during cylinder removal.

c. Tag and disconnect hydraulic lines to cylinder. (Wipe connections clean prior todisconnecting).

d. Cap and plug open ports and lines.e. Use a portable hoist or sling to support cylinder weight during pin removal.f. Remove nut and pivot pin from rod end.g. Remove nut and pivot pin from base end.

h. Remove cylinder with portable hoist or similar device.

WARNING

WARNING

DO NOT MOVE A HYDRAULIC CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE CAN BEHURT BY THE MACHINES MOVEMENT.


CONVEYOR SUPPORT PROPS MUST BE USED ANYTIME MAINTENANCE IS PERFORMED WITH THECONVEYOR IN THE RAISED POSITION.

DO NOT HIT OR BUMP CONVEYOR FRAME OR SUPPORT PROP DURING CYLINDER REMOVAL.

CAUTIONWIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM.

CAP OR PLUG ALL OPEN PORTS AND LINES.

CAUTIONUSE BACK-UP WRENCHES ON ALL MATING FITTINGS.

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2. Rear conveyor lift cylinder installation procedure: (See Figure 2-3-24)

a. Using a portable hoist or similar device, position cylinder with cylinder base mount alignedwith frame mounting bracket.

b. Insert pivot pin through frame mounting bracket, cylinder base mounting hole and installpivot pin nut. (Tighten nut securely)

c. Connect hydraulic lines to cylinder.d. Energize unit and hydraulically extend cylinder rod to lift frame mounting bracket.e. Align cylinder rod mounting hole and lift frame mounting bracket holes.f. Insert pivot pin through aligned holes and install nut. (Tighten nut securely)

g. Bleed air from system.h. Energize unit, raise rear of conveyor and stow away conveyor support prop.

REAR CONVEYOR LIFT CYLINDERFIGURE 2-3-24

WARNINGDO NOT HIT OR BUMP CONVEYOR FRAME OR SUPPORT PROP DURING CYLINDERINSTALLATION.

WARNINGSTAND CLEAR OF CONVEYOR UNTIL ALL AIR HAS BEEN BLED FROM SYSTEM.

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Z. Front Conveyor Lift Cylinder1. Front conveyor lift cylinder removal procedure: (See Figure 2-3-25)

a. Raise front of belt conveyor either hydraulically or with a hoist and sling (while holding frontlift cylinder control valve open).

b. Lower front conveyor support prop to support conveyor weight during cylinder removal.

c. Tag and disconnect hydraulic lines to cylinder. (Wipe connections clean prior todisconnecting).

d. Cap and plug open ports and lines.e. Use a portable hoist or sling to support cylinder weight during pin removal.f. Remove nut and pivot pin from rod end.g. Remove nut and pivot pin from base end.

h. Remove cylinder with portable hoist or similar device.

WARNING

WARNING

DO NOT MOVE A HYDRAULIC CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE CAN BEHURT BY THE MACHINES MOVEMENT.


CONVEYOR SUPPORT PROPS MUST BE USED ANYTIME MAINTENANCE IS PERFORMED WITH THECONVEYOR IN THE RAISED POSITION.

DO NOT HIT OR BUMP CONVEYOR FRAME OR SUPPORT PROP DURING CYLINDER REMOVAL.

CAUTIONWIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM.

CAP OR PLUG ALL OPEN PORTS AND LINES.

CAUTIONUSE BACK-UP WRENCHES ON ALL MATING FITTINGS.

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2. Front conveyor lift cylinder installation procedure: (See Figure 2-3-25)

a. Using a portable hoist or similar device, position cylinder with cylinder base mount alignedwith frame mounting bracket.

b. Insert pivot pin through frame mounting bracket, cylinder base mounting hole and installpivot pin nut. (Tighten nut securely)

c. Connect hydraulic lines to cylinder.d. Energize unit and hydraulically extend cylinder rod to lift frame mounting bracket.e. Align cylinder rod mounting hole and lift frame mounting bracket holes.f. Insert pivot pin through aligned holes and install nut. (Tighten nut securely)

g. Bleed air from system.h. Energize unit, raise front of conveyor and stow away conveyor support prop.

FRONT CONVEYOR LIFT CYLINDERFIGURE 2-3-25

WARNINGDO NOT HIT OR BUMP CONVEYOR FRAME OR SUPPORT PROP DURING CYLINDERINSTALLATION.

WARNINGSTAND CLEAR OF CONVEYOR UNTIL ALL AIR HAS BEEN BLED FROM SYSTEM.

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IV.TROUBLE SHOOTING

A. General InformationThe following section lists possible problems that may be encountered when operating or servicing the

Model CBL200E Mobile Belt Conveyor and can aid in locating and correcting these problems.

1. It is IMPORTANT to be familiar with and know the normal operation of this unit beforeattempting to bring it back to proper operation. This is especially true with the electrical portionof the unit. Due to the numerous interlocks present, the possibility of non-operation is present.

2. Whenever a potential problem is uncovered during operation or maintenance, the unit should beremoved from service and the problem corrected by a qualified maintenance technician.

2. See the Electronic Motor Control Section of Chapter 5 before attempting to trouble shoot theelectronics on the unit.

3. Do not megger or highpot the Solid State portion of the machine’s electrical wiring.

4. Do not expose the Solid State portion of the machine to high temperatures or water.

WARNINGWHEN TROUBLE SHOOTING THE UNIT:

ALWAYS CHOCK ALL FOUR (4) TIRES IN EACH DIRECTION OR RAISE THE UNIT CLEAR OF THEGROUND SO THAT TIRES ARE FREE TO ROTATE.

DISCONNECT THE BATTERIES EXCEPT WHEN VOLTAGE CHECKS ARE BEING MADE.

USE INSULATED GLOVES AND TOOLS WHEN WORKING INSIDE THE ELECTRICALCONTROLLER.


DO NOT MOVE AND CONTROL LEVER UNLESS YOU ARE CERTAIN THAT NO ONE COULD BEHURT BY THE MACHINE’S MOVEMENT.

DO NOT PERFORM MAINTENANCE OR TROUBLE SHOOT THE MACHINE IN A CONJESTED AREAPro

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B. Hydraulic System (General)

Trouble, Symptom OrCondition Probable Cause Test, Check Or Remedy

Dirty Oil 1. Components not properlycleaned after servicing.

2. Hose connections not properlycovered plugged or cappedduring servicing of machine.

3. Hydraulic tank strainers notreplaced at proper intervals orwhen indicated.

1. Disassemble components andclean parts.

2. Clean hose connections.

3. Replace or clean strainers atproper intervals.

Foaming Oil 1. Return tank line not below fluidlevel.

2. Oil contaminated withincompatible material.

3. Suction leak to pump aeratingoil.

1. Check hydraulic fluid level.

2. Drain oil and replace withclean oil.

3. Replace or tighten fittings orlines.

Moisture in Oil 1. Soluble oil solution splashinginto poorly gasketed tank or fillcap left off.

2. Moisture in oil storagecontainers or usedreplacement oil.

3. Extreme temperaturedifferential in certaingeographical locations.

1. Drain oil and refill with cleanoil. Check fill cap to see if itis properly closed.

2. Replace or clean oil storagecontainers.

3. Replace with recommended oilfor correct temperature range.

Foreign Matter SourcesIn The Circuit

1. Sealing Compound (pipe dope,teflon tape) in circuit.

2. Burrs inside pipingcomponents.

3. Lines left unprotected anddirty during parts replacement.

4. Replacement parts notproperly protected duringstorage.

1. Clean or replace seals.

2. Disassemble piping andremove any burrs.

3. Drain and replace oil.

4. Clean parts thoroughly beforeinstallation.

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Overheating of System 1. Fluid viscosity too high.

2. Excessive slippage or internalleakage past pump orcylinders.

3. Improper air circulation aroundreservoir.

1. Check fluid specs.

2. Fluid viscosity too low.

3. Check to see if the areaaround the reservoir is clear.

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C. Brakes (Service)


Brakes Slow To Apply 1. Defective front brake caliper.

2. Defective rear brake cylinder.

3. Brake lines or fittings leakingor damaged.

4. Pedal linkage out ofadjustment.

5. Defective master cylinder.

6. Low brake fluid level or air insystem.

1. Replace or repair caliper.

2. Replace or repair cylinder.

3. Check for leaks and repair.

4. Adjust linkage.

5. Repair or replace mastercylinder.

6. Check fluid level and bleedbrakes if required.

Brakes Won’t Release 1. Pedal linkage out ofadjustment or binding.

2. Defective brake pads orshoes.


4. Defective brake caliper.

1. Check for proper adjustmentor binding.

2. Check pads or shoes.

3. Replace master cylinder.

4. Repair or replace brakecaliper.

Insufficient Brakes 1. Pedal linkage out ofadjustment.

2. Brake line mashed.

3. Worn brake pads or shoes.


5. Low brake fluid level or air insystem.

1. Adjust linkage.

2. Check lines and replace.

3. Replace pads or shoes.


5. Check fluid level and bleedbrakes if required.

Brakes Will Not ReleaseCompletely

1. Defective front caliper.


3. Air in brake system.



2. Repair or replace brakecylinder.

3. Bleed brakes.


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Excessive Braking 1. Defective front caliper.




2. Repair or replace brakecylinder.


No Brakes 1. Pedal linkage out ofadjustment.

2. Brake line mashed or broken.

3. Worn brake pads or shoes.


1. Adjust linkage.

2. Check lines and replace.

3. Replace pads or shoes.


Excessive Pedal Travel OrPedal Goes to FloorConsistently

1. Low fluid level.

2. Rear brake shoes out ofadjustment or worn.

3. Front brake pads worn.

4. Loose or improper alignmentof pedal to master cylinderlinkage.

1. Check fluid level.

2. Adjust or replace brake shoes.

3. Replace pads.

4. Repair or replace as required.

Brake Pedal Feels SpongyWhen Applied

1. Low fluid level.

2. Rear brake shoes out ofadjustment or worn.

3. Front wheel bearings out ofadjustment.

4. Disc brake caliper attachmentloose.

5. Worn or damaged rear selfadjusters.

1. Check fluid level.

2. Adjust or replace brake shoes.

3. Adjust bearings.

4. Tighten or replace as required.


Noise At Wheels When BrakesAre Applied (Squeaks OrChatter).

1. Worn or scored brake drumsand lining or rotors and pads.

2. Missing or damaged brakepad insulators.

3. Burrs or rust on rotor or drum.

1. Inspect, repair or replace asrequired.


3. Clean or de-burr as required.

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Noise At Wheels When BrakesAre Applied (Squeaks OrChatter).(Continued)

4. Dirty, greased or glazed padsor shoes.

4. Clean or replace as required.

Brakes Pull To One Side 1. Unequal air pressure in tires.

2. Grease or fluid on pads orshoes.

3. Loose or missing disc brakecaliper attaching bolts.

4. Restricted brake lines orhoses.

5. Worn Or Damaged Rear SelfAdjusters.

1. Check and adjust air pressure.

2. Clean or replace as required.

3. Replace missing bolts andtighten to proper torque.

4. Repair Or Replace AsRequired.


Brake Warning Light Is On 1. Low fluid level.

2. Worn or damaged brakewarning switch.

3. Worn or damaged mastercylinder.

1. Add fluid, check for leaks andbleed system.

2. Replace switch.


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D. Brake (Park Brake)


Brake Slow To Apply 1. Defective brake caliper.

2. Cable or linkage out ofadjustment.

3. Cable or linkage damaged orbinding.

4. Worn brake pads.


2. Adjust cable or linkage.

3. Repair or replace cable orlinkage.

4. Replace pads.

Brake Won’t Release 1. Defective brake caliper.




Insufficient Brakes 1. Defective brake caliper.



4. Worn brake pads.




4. Replace pads.

Brake Will Not ReleaseCompletely

1. Defective brake caliper.






Excessive Braking 1. Defective brake caliper.




Parking Brake Lever Hard ToApply

1. Brake handle out ofadjustment.

2. Frozen or damaged brakecable.

1. Adjust or repair as required.


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E. Hydraulic Cylinders


Cylinder Drifts 1. Piston seal leak.

2. Other circuit leaks.

1. Replace seals.

2. Correct leaks.

Cylinder Fails To Move TheLoad When Actuated

1. Pressure to low.

2. Piston seal leak.

3. Piston rod broken at pistonend.

4. Contamination in hydraulicsystem resulting in scoredcylinder bore.

1. Check pressure at cylinder tomeet circuit requirements.

2. Replace seals.

3. Disassemble and replacepiston rod.

4. Disassemble and replacenecessary parts.

Erratic Or Chatter In Operation 1. Excessive friction due tomisalignment.

1. Correct cylinder to loadalignment.

Excessive Or Rapid PistonWear

1. Excessive high back pressuredue to over adjustment.

1. Correct pressure adjustment.

Cylinder Body Seal Leak 1. Excessive pressure.

2. Seal is pinched or extruded.

3. Seal deterioration (soft orgummy).

1. Reduce pressure to ratedlimits.

2. Replace cylinder body seal.

3. Check compatibility of sealmaterial with operating fluid.Replace oil.

Piston Is Leaking 1. Contamination has scored thepiston or rod.

1. Replace rod or piston.

Piston Freezes To The Tube 1. Scoring in the piston. 1. Replace piston.

Packing And Gasket LeaksDevelop

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F. Hydraulic Pump


Pump Makes Excessive Noise 1. Vacuum leak in suction line.

2. Vacuum leak in pump shaftseal.

3. Poor alignment with drivemotor.

4. Incorrect fluid in system.

5. Seal deterioration (hard or lossof elasticity).

6. Seal deterioration (loss ofradial squeeze due to flatspots or wear on O.D. or I.D.).

1. Check for leaks in fittings ordamaged suction line.

2. Repair or replace pump.

3. Align pump and pump motor.

4. Check fluid specs.

5. Replace seal.

6. Replace seal.

Seal Leak 1. Torn or worn seal.

2. Gland bearing worn.

3. Seal deterioration (soft orgummy).

4. Seal deterioration (hard or lossof elasticity).

5. Seal deterioration (loss ofradial squeeze due to flatspots or wear on O.D. or I.D.).

6. Aeration of fluid in tank.

7. Worn or damaged gears andhousing.

8. Worn or faulty bearing.

9. Plugged or restricted suctionline or strainer.

10. Oil viscosity too high oroperating temperature too low.

1. Replace seal.

2. Replace gland and seals.

3. Replace seal.

4. Replace seal.

5. Replace seal.

6. Correct air leak.

7. Replace gears and housing.

8. Replace faulty bearing.

9. Clean or replace suction lineor strainer.

10. Replace with recommended oil

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Seal Leak (Continued) 11. Air leak in suction line orfittings.

12. Loose or worn pump parts.

13. Air leak at pump shaft seal.

14. Oil level too low.

15. Air bubbles in intake oil.

16. Pump housing bolts loose ornot properly torqued.

11. Replace line or fittings if badlyworn.

12. Replace worn pump parts.

13. Replace seal.

14. Check oil level.

15. Check oil level and tighten anyloose fittings.

16. Tighten and re-torque bolts.

Pump Failure to Deliver Oil 1. Low oil level in tank.

2. Suction strainer plugged.

3. Air leak in suction line andpreventing priming.

4. Pump shaft turning too slowly.

5. Oil viscosity too high.

6. Incorrect shaft rotation.

7. Pump shaft or parts broken.

8. Dirt or contamination in pump.

1. Check oil level.

2. Replace Clean or replacestrainer.

3. Tighten or replace suction line.

4. Gears are worn and needreplacing.

5. replace with recommended oil.

6. Check pump motor wiring.

7. Replace shaft or broken parts.

8. Clean pump.

Oil Leakage Around Pump 1. Shaft seal worn.

2. Hydraulic line connectionleaking.

3. Pump housing bolts loose orimproperly torqued.

1. Replace seal.

2. Tighten or replace fittings.

3. Tighten and re-torque bolts.

Excessive Pump Wear 1. Abrasive dirt or contaminationin hydraulic oil beingcirculated through the system.

2. Pump misalignment.

1. Clean tank and refill with cleanoil.

2. Realign pump.

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Excessive Pump Wear(Continued)

3. Oil viscosity too low.

4. System pressure exceedingpump rating.

3. Replace with recommendedoil.

4. Check system pressure.

Pump Parts Inside The HousingAre Broken

1. Seizure due to lack of oil.

2. Excessive system pressureabove maximum pump rating.

3. Excessive torquing to housingbolts.

4. Contamination being drawn infrom tank.

1. Check oil level.


3. Re-torque housing bolts.

4. Clean tank and replace withclean oil.

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G. Steering


Machine Pulls To One SideWhile Traveling

1. Unequal air pressure in tires.

2. Toe-in out of adjustment.

3. Front wheel bearings worn orout of adjustment.

1. Check and adjust air pressure.

2. Check steering tie rod fordamage and adjust toe-in.

3. Replace or adjust bearings asrequired.

Steering Very Difficult 1. Low oil level in tank.

2. System pressure too low.

3. Pump motor is not operating.

4. Pump not operating ordelivering correct oil pressure.

1. Check oil level.


3. See Pump Motor TroubleShooting.

4. See Hydraulic Pump TroubleShooting.

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H. Pump Motor


Pump Motor Won’t Start 1. Usually control trouble. 1a. Check source of powersupply.

1b. Check overloads, fuses,controls, etc.

Pump Motor Makes ExcessiveVibrations

1. Poor alignment with hydraulicpump.

2. Rubbing between rotating andstationary parts.

3. Armature out of balance.

4. Resonance.

1. Align pump motor and pump.

2. Locate and repair cause ofrub.

3. Check rotor balance and repairas required.

4. Tune system.

Excessive Humming 1. High voltage.

2. Loose pole pieces.

1. Check input voltage and forproper connection.

2. Re-tighten bolts.

Motor Over Heating 1. Overload. Compare actualamps to the nameplate rating.

2. Improper ventilation.

3. Armature rubbing on stator.

4. Field over-voltage.

5. Open armature windings.

6. Full voltage on field at standstill.

7. Ground.

8. Improper connections.

1. Check for excessive friction inmotor or pump.

2. Check to see that the areaaround the motor is clear.

3. Check for bad bearings.

4. Check voltage.

5. Check field commutator forburned bars.

6. Reduce voltage to 60% withfield economy circuit incontrol.

7. Locate and repair.

8. Check all connections perWiring Diagram in Chapter 4.

Pump Motor Makes ExcessiveNoise

1. Foreign material in air gap orventilation openings.

1. Remove armature and foreignmaterial, replace armature.Check the integrity of theinsulation and ventilationopenings.

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Bearing Over Heating 1. Misalignment.

2. Too much grease in bearing.

3. Insufficient grease in bearing.

4. Dirt or contaminants inbearing.

1. Align pump motor and pump.

2. Remove grease until cavity isabout ¾ full.

3. Add grease until cavity isabout ¾ full.

4. Clean bearing and bearingcavity. Repack with correctgrease.

Growling Or Whining 1. Bad bearing. 1. Replace bearing. Purge andreplace grease.

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I. Rear Drive


Drive Motor Won’t Start 1. Usually control trouble. 1a. Check source of powersupply.


Excessive Noise Or Vibration 1. Drive motor.

2. Bad u-joint in drive line.

3. Drive shaft out of balance.

4. Differential oil level low.

5. Rear brake problem.

6. Differential problem.

7. Axle shaft broken or badbearing.

1. See Drive Motor TroubleShooting.

2. Replace u-joint.

3. Check drive shaft balance.

4. Check oil level and refill asrequired. Check for leaks.

5. See Brakes (Service) TroubleShooting).

6. Check differential, repair orreplace as required.

4. Check axle shafts andbearings, repair or replace asrequired.

Hub Area Or Differential OverHeating

1. Differential oil level low.

2. Bad bearing.

1. Check oil level and refill asrequired. Check for leaks.

2. Check bearings and replaceas required.

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J. Rear Drive Motor


Drive Motor Won’t Start 1. Usually control trouble. 1a. Check source of powersupply.


Drive Motor Makes ExcessiveVibrations

1. Poor alignment with drive line



4. Resonance.

1. Align motor and drive line.



4. Tune system.











7. Ground.


1. Check for excessive friction inmotor or drive line.



4. Check voltage.





Drive Motor Makes ExcessiveNoise

1. Foreign material in air gap orventilation openings.


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1. Align drive motor and driveline.





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K. 12V Converter


No 12V Output 1. Blown fuse. 1. Replace fuse. If fuse blows atonce, replace converter.

Fuse OK And No 12V Output 1. Converter output.

2. Faulty wiring.

1. Check converter output for12V output.

2. Check and repair wiring asrequired.

Fuse And Wiring OK, No 12VOutput

1. Bad converter. 1. Replace converter.

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L. Electronic Motor Control

Fault conditions will be indicated on the readout panel by two different readouts.

1. P- This readout indicates an operation by the driver that was incorrect. If a P appears,restart the unit.

2. F- This readout indicates a system or component failure. No further operation of the unitwill be permitted until the problem is repaired.

Display Description CauseP.01 Incorrect power up sequence. Accelerator pressed or direction chosen

before main switch closed.P.02 Incorrect drive selection. Accelerator pressed before a direction

chosen.P.03 Inching direction and direction lever used at

same time.Use one or the other.

P.04 Hand brake “ON”. Hand brake not released.P.05 Foot brake “ON”. Warning only given.P.06 Seat switch (optional). Operator out of seat.P.07 Inching with (optional) seat switch closed. Inching works only if all operator controls are

in “NEUTRAL”.P.08 Not usedP.09 Not usedP.10 Not usedP.11 Thermal cutback. Over heating on SCR Panel (Unit will move

slowly).P12 - P20 Not usedF.21 - F49 Require some type of repair or component replacement. Refer to Chapter 5, for more detailed

descriptions of the fault condition.

NOTICETHE ELECTRONIC MOTOR CONTROL INSTALLED ON THIS UNIT WILL PREVENT OPERATION IF AFAULT CONDITION OCCURS.

WARNINGWHILE PERFORMING TROUBLE SHOOTING PROCEDURES ON THIS UNIT, THE WHEELS MUST BERAISED CLEAR OF THE GROUND SO THEY ARE FREE TO ROTATE AND THE BATTERIESDISCONNECTED. THE BATTERIES SHOULD BE CONNECTED ONLY AS REQUIRED FOR TESTING.

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M.Conveyor Lift System


Front And Rear Lift CylindersWill Not Raise Conveyor.

1. Low oil level in tank.

2. Defective pump drive motor.

3. Defective hydraulic pump.

4. Defective lift control valve.

5. Defective hydraulic cylinder.

1a. Check oil level.

1b. Check for leaks and repair ifrequired.

2. Repair or replace drive motor.(See Pump Motor TroubleShooting).

3. Repair or replace pump.(See Pump Trouble Shooting).

4. Repair or replace.

5. Repair or replace. (SeeHydraulic Cylinder TroubleShooting).

Conveyor Raises Too Slowly 1. Low oil level in tank.

2. Defective hydraulic pump.

3. Defective lift control valve.

4. Defective hydraulic cylinder.

5. Defective cylinder load holdingvalve.

6. Incorrect system pressure.

1a. Check oil level.

1b. Check for leaks and repair ifrequired.

2. Repair or replace pump.(See Pump Trouble Shooting).


4. Repair or replace. (SeeHydraulic Cylinder TroubleShooting).


6a. Check hydraulic hoses forrestrictions or leaks.

6b. Check hydraulic tank suctionstrainer. Clean or replace asrequired.

Conveyor Creeps Down WithControl Valve In “NEUTRAL”Position

1. Internal leak in cylinder orvalve.

1. Repair or replace as required.(See Hydraulic CylinderTrouble Shooting).

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N. Conveyor Belt


Conveyor Belt Will Not Run InEither “FORWARD” Or“REVERSE” When The SwitchIs Actuated

1. Defective “FORWARD” or“REVERSE” control switch.

2. Belt drive chain broken.

3. Defective drive motor.

4. Defective reducer.

5. Sheared shaft key.

6. Defective wiring.



3. Repair or replace motor.(See Conveyor Drive MotorTrouble Shooting).


5. Replace shaft key. (CheckDrive motor shaft, reducershaft, idler shaft and driveroller shaft).


Cargo Belt Speed To Slow 1. Defective speed controlswitch.

2. Loose conveyor belt.

3. Defective drive motor.

4. Binding in belt drive or rollers.

5. Load capacity of conveyorexceeded.

6. Conveyor angle too steep.


2. Adjust or replace as required.

3. Repair or replace motor.(See Conveyor Drive MotorTrouble Shooting).

4. Adjust, lubricate, repair orreplace.

5. Load capacity is 2,000 lbs.

6. For conveyor anglesexceeding 15º, the loadcapacity must be reducedbelow 2,000 lbs.

Excessive Noise Or Vibration 1. Defective drive motor.

2. Defective conveyor brake.

3. Defective reducer.

4. Reducer oil level low.

1. Repair or replace. (SeeConveyor Drive Motor Troubleshooting).

2. Repair or replace. (SeeConveyor Brake Troubleshooting).


4. Check oil level.

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Excessive Noise Or Vibration(Continued)

5. Drive chains loose or out ofadjustment.

6. Bad rollers or roller bearings.

5. Adjust, repair or replace asrequired.

6. Check rollers and rollerbearings. Repair or replace asrequired.

Cargo Belt Does not TrackProperly

1. Rollers out of adjustment. 1. Adjust.

Belt Will Not Stop When“STOP” Button Is Actuated

1. Defective conveyor brake. 1. Repair or replace. (SeeConveyor Brake Troubleshooting).

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O. Conveyor Drive Motor


Pump Motor Won’t Start 1. Usually control trouble. 1a. Check source of powersupply.


Motor Makes ExcessiveVibrations

1. Poor alignment with conveyorbrake and reducer.



4. Resonance.

1. Check alignment.



4. Tune system.











7. Ground.


1. Check for excessive friction inmotor, brake, or reducer.



4. Check voltage.





Motor Makes Excessive Noise 1. Foreign material in air gap orventilation openings.


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1. Align motor, brake andreducer.





Note:See chapter 5 for more detailed information on the conveyor drive motor.

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P. Conveyor Brake


Conveyor Coasting 1. Brake disc worn.

2. Excessive cycle rate.

3. Friction surfacescontaminated.

4. Brake worn out.

1. Replace brake disc.

2. Reduce cycle rate.

3. Replace friction disc.

4. Replace friction disc.

Brake Not Releasing 1. Open Circuit.

2. Improper or no voltage tobrake.

3. Adjustment required.

4. Manual release out ofadjustment.

1. Check for pinched or brokenwires.

2. Check for proper voltage.

3. Adjust.

4. Adjust.

Motor Stalled 1. Brake not releasing. 1. See Brake Not ReleasingSymptom.

High Housing Temperature 1. Excessive cycle rate.

2. High ambient temperature.

3. Excessive load inertia.

4. Brake not releasing.

1. Reduce cycle rate.

2. Reduce cycle rate and/or loadinertia.

3. Reduce load inertia.

4. See Brake Not ReleasingSymptom.

Note:See chapter 5 for more detailed information on the conveyor brake.

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a. general maintenance instructions 1-1 b. …a.general maintenance instructions long reliable...

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