PDCE 40 - Big Lift, LLC Support Site for Big Joe Equipment · · 2008-11-04pdce 40 power driven counterbalanced electronic power steering ... brand control valve repair..... 9-5

Big Joe Manufacturing Company MANUAL NO. 902998

www.bigjoemfg.com REV A 11/3/08

PDCE 40POWER DRIVEN COUNTERBALANCED

ELECTRONIC POWER STEERINGLIFT TRUCK

Operation

Maintenance

Repair Parts List

TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION ............................................................1-11-1. INTRODUCTION..............................................1-11-2. GENERAL DESCRIPTION...............................1-11-3. SAFETY FEATURES. ......................................1-21-4. OPTIONS AND ACCESSORIES......................1-21-5. SAFETY SYMBOLS. ........................................1-2

2 OPERATION ...............................................................2-12-1. GENERAL. .......................................................2-12-2. OPERATING PRECAUTIONS. ........................2-12-3. BEFORE OPERATION.....................................2-22-4. INSTRUMENTS AND CONTROLS..................2-42-4.1. STEERING ARM AND CONTROL HEAD........2-42-4.2. LIFT/LOWER AND TILT CONTROL. ...............2-52-4.3. BATTERY DISCONNECT. ...............................2-52-4.4. OPTIONAL FEATURES. ..................................2-52-5. OPERATION ....................................................2-52-5.1. FORWARD AND REVERSE TRAVEL AND

SPEED CONTROL..........................................2-52-5.2. STEERING. ......................................................2-52-5.3. STOPPING.......................................................2-62-5.4. PARKING. ........................................................2-62-5.5. BATTERY CHARGING.....................................2-72-5.6. LOAD HANDLING. ...........................................2-72-5.7. MOVING A DISABLED TRUCK .......................2-7

3 PLANNED MAINTENANCE ........................................3-13-1. GENERAL. .......................................................3-13-2. MONTHLY AND QUARTERLY CHECKS. .......3-13-3. BATTERY CARE..............................................3-13-3.1. GENERAL. .......................................................3-13-3.2. BATTERY SERVICING. ...................................3-13-4. LUBRICATION. ................................................3-13-5. LIFT CHAIN MAINTENANCE...........................3-1

4 TROUBLESHOOTING ................................................4-14-1. GENERAL ........................................................4-1

5 CONTROL ARM AND CONTROL HEAD SERVICING.................................................................5-15-1. GENERAL. .......................................................5-15-2. COLD CONDITIONING....................................5-15-3. BELLY-BUTTON SWITCH ADJUSTMENT. .....5-15-1. POTENTIOMETER TESTING AND

ADJUSTMENT .................................................5-35-2. CONTROL HEAD SWITCH REPLACEMENT..5-35-3.1. BELLY-BUTTON SWITCH ..............................5-35-3.2. LIFT SWITCH, LOWER SWITCH OR

HORN SWITCH................................................5-35-3.3. SPEED CONTROL SWITCHES AND

RETURN SPRING............................................5-45-3.4. POTENTIOMETER...........................................5-45-3. STEERING ARM. .............................................5-65-3.5. RETURN SPRING ADJUSTMENT...................5-65-3.6. RETURN SPRING REPLACEMENT................5-65-4. ELECTRICAL CONTROL CABLE

REPLACEMENT...............................................5-6

6 BRAKE SERVICING....................................................6-16-1. DEADMAN SWITCH ADJUSTMENT ...............6-16-2. DEADMAN SWITCH REPLACEMENT ............6-1

7 TRANSMISSION, DRIVE WHEEL AND LOAD WHEEL SERVICING7-1

7-1. DRIVE WHEEL REMOVAL ............................. 7-17-2. TRANSMISSION, MOTOR AND BRAKE

REMOVAL ....................................................... 7-17-3. TRANSMISSION, MOTOR AND BRAKE

INSTALLATION ............................................... 7-37-1. LOAD WHEELS............................................... 7-6

8 ELEVATION SYSTEM SERVICING ........................... 8-18-1. GENERAL........................................................ 8-18-2. RAM HEAD REPLACEMENT.......................... 8-18-2.1. NON-TELESCOPIC......................................... 8-18-2.2. TELESCOPIC .................................................. 8-28-3. LIFT CHAIN ADJUSTMENT ............................ 8-28-3.1. NON-TELESCOPIC......................................... 8-28-3.2. TELESCOPIC .................................................. 8-28-4. LIFT CHAIN INSPECTION .............................. 8-28-5. LIFT CHAIN REPLACEMENT ......................... 8-28-5.1. NON-TELESCOPIC......................................... 8-28-5.2. TELESCOPIC .................................................. 8-48-6. LIFT CYLINDER REMOVAL............................ 8-48-7. TILT CYLINDER REPLACEMENT. ................. 8-48-8. MAST REMOVAL. ........................................... 8-68-9. LIFT CARRIAGE REPLACEMENT.................. 8-6

9 HYDRAULIC SYSTEM SERVICING........................... 9-19-1. RELIEVING SYSTEM PRESSURE. ................ 9-19-1. FILTER REPLACEMENT

(Two Piece Pump and Reservoir). .................. 9-29-2. HYDRAULIC PUMP AND MOTOR ASSY

(Two Piece Pump and Reservoir) .................... 9-29-3. LINE, FITTING and HOSE REPLACEMENT... 9-39-4. CONTROL VALVE SERVICE.......................... 9-49-4.1. CONTROL VALVE REPLACEMENT............... 9-49-1.1. BRAND CONTROL VALVE REPAIR............... 9-59-5. FLOW CONTROL VALVE REPLACEMENT ... 9-99-5.1. LIFT FLOW CONTROL VALVE....................... 9-99-5.2. TILT FLOW CONTROL VALVE....................... 9-99-6. LIFT CYLINDER REPAIR.............................. 9-129-7. TILT CYLINDER REPAIR.............................. 9-13

10 ELECTRICAL COMPONENTS ................................. 10-110-1. ELECTRICAL CONTROL PANEL ................. 10-110-2. HIGH SPEED LIMIT SWITCH ....................... 10-310-2.1.OPERATIONAL CHECK................................ 10-310-2.2.HIGH SPEED LIMIT SWITCH

ADJUSTMENT............................................... 10-310-3. PUMP MOTOR. ............................................. 10-310-4. DRIVE MOTOR. ............................................ 10-310-5. BATTERIES................................................... 10-3

11 OPTIONAL EQUIPMENT ......................................... 11-111-1. KEYSWITCH ................................................. 11-111-2. REMOTE CONTROL..................................... 11-111-3. HOUR METER/BATTERY CAPACITY

INDICATOR ................................................... 11-111-4. LIFT LIMIT SWITCH OVERRIDE .................. 11-1

12 ILLUSTRATED PARTS BREAKDOWN.................... 12-1

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LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 NAME PLATE ..................................................... 1-11-2 PDCE LIFT TRUCK ............................................ 1-32-1 LOAD CENTER................................................... 2-12-2 SAMPLE OF OPERATOR CHECK LIST ............ 2-32-3 CONTROL HEAD................................................ 2-42-4 LIFT/LOWER LEVER.......................................... 2-52-5 OPTIONAL REMOTE LIFT/LOWER CONTROL 2-52-6 CONTROL ARM BRAKING POSITIONS............ 2-63-1 LUBRICATION DIAGRAM ................................. 3-34-1 ELECTRICAL WIRING DIAGRAM (SHEET 1) ... 4-44-1 ELECTRICAL WIRING DIAGRAM (SHEET 2) ... 4-55-1 BELLY-BUTTON SWITCH ADJUSTMENT......... 5-15-2 CONTROL HEAD ASSEMBLY ........................... 5-25-3 CONTROL HEAD POTENTIOMETER

ADJUSTMENT.................................................... 5-35-4 CONTROL ARM.................................................. 5-55-5 SWITCH HARNESS CONNECTION .................. 5-75-6 BASE AND FRAME ............................................ 5-85-7 ELECTRICAL CONTROL CABLE

REPLACEMENT ................................................. 5-96-1 BRAKE ENGAGE/DISENGAGE ......................... 6-16-2 BASE AND FRAME ............................................ 6-26-3 CONTROL ARM.................................................. 6-37-1 PIVOT CAP REMOVAL ...................................... 7-17-2 AC DRIVE AND STEERING SYSTEM ............... 7-27-3 BASE AND FRAME ............................................ 7-37-4 CONTROL ARM.................................................. 7-47-5 ELECTRICAL SYSTEM COMPONENTS ........... 7-57-6 LOAD WHEELS .................................................. 7-68-1 ELEVATION SYSTEM (NON-TELESCOPIC)..... 8-18-2 ELEVATION SYSTEM (TELESCOPIC) .............. 8-38-3 STANDARD HYDRAULIC SYSTEM................... 8-59-1 PUMP AND RESERVOIR HYDRAULIC

SYSTEM ............................................................. 9-19-2 HYDRAULIC PUMP AND MOTOR ASSEMBLY. 9-29-3 PUMP AND RESERVOIR HYDRAULIC

SYSTEM ............................................................. 9-39-4 ACCESS COVERS ............................................. 9-49-5 BRAND 2 SPOOL CONTROL VALVE

WITH LEVERS.................................................... 9-59-6 BRAND 3 SPOOL CONTROL VALVE

WITH LEVERS.................................................... 9-59-7 HYDRAULIC SYSTEM

(2 SPOOL BRAND VALVE) ................................ 9-69-8 HYDRAULIC SYSTEM

(3 SPOOL BRAND VALVE) ................................ 9-79-9 HYDRAULIC SYSTEM

(2 SPOOL BUCHER VALVE).............................. 9-8

9-10 STANDARD HYDRAULIC SYSTEM ................. 9-109-11 AUXILIARY HYDRAULIC SYSTEM .................. 9-119-12 LIFT CYLINDER................................................ 9-129-13 TILT CYLINDER................................................ 9-1310-1 ACCESS COVERS............................................ 10-110-2 ELECTRICAL SYSTEM COMPONENTS.......... 10-212-1 STEERING ARM ............................................... 12-212-2 CONTROL HEAD ASSEMBLY.......................... 12-412-3 CONTROL HEAD COLD CONDITIONING ....... 12-612-4 BASE AND FRAME........................................... 12-812-5 AC DRIVE AND STEERING SYSTEM............ 12-1012-6 TRANSMISSION ............................................. 12-1212-7 DECAL LOCATION ......................................... 12-1412-8 ELEVATION SYSTEM (NON-TELESCOPIC) . 12-1612-9 ELEVATION SYSTEM (TELESCOPIC) .......... 12-1812-10 LIFT CARRIAGE ............................................. 12-2012-11 PUMP AND RESERVOIR HYDRAULIC

SYSTEM.......................................................... 12-2212-12 PUMP AND RESERVOIR HYDRAULIC

SYSTEM.......................................................... 12-2412-13 STANDARD HYDRAULIC SYSTEM ............... 12-2612-14 HYDRAULIC SYSTEM

(2 SPOOL BRAND VALVE)............................. 12-2812-15 HYDRAULIC SYSTEM

(3 SPOOL BRAND VALVE)............................. 12-3012-16 HYDRAULIC SYSTEM

(2 SPOOL BUCHER VALVE) .......................... 12-3212-17 AUXILIARY HYDRAULIC SYSTEM ................ 12-3412-18 HYDRAULIC PUMP AND MOTOR ASSY....... 12-3612-19 BRAND 2 SPOOL CONTROL VALVE

WITH LEVERS ................................................ 12-3712-20 BRAND 3 SPOOL CONTROL VALVE

WITH LEVERS ................................................ 12-3812-21 BUCHER CONTROL VALVE .......................... 12-3912-22 BRAND STACK CONTROL VALVE................ 12-4012-23 STACK VALVE SWITCH................................. 12-4112-24 STACK VALVE SEAL KIT ............................... 12-4112-25 LIFT CYLINDER.............................................. 12-4212-26 TILT CYLINDER.............................................. 12-4312-27 ELECTRICAL SYSTEM COMPONENTS........ 12-4412-28 ELECTRIC PANEL ASSEMBLY...................... 12-4612-29 DRIVE MOTOR ............................................... 12-4812-30 PUMP MOTOR................................................ 12-4912-31 KEY SWITCH .................................................. 12-5012-32 REMOTE LIFT AND LOWER SCHEMATIC.... 12-5212-33 HOUR METER/BATTERY CAPACITY

INDICATOR..................................................... 12-5412-34 LIFT LIMIT SWITCH W/ OVERRIDE............... 12-55

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LIST OF TABLES

Table Page Table Page

2-1 OPERATOR CHECKS .........................................2-22-2 CONTROL HEADS...............................................2-43-1 INSPECTION AND SERVICE CHART.................3-23-2 RECOMMENDED LUBRICANTS AND OILS .......3-2

3-3 HYDRAULIC OIL CAPACITY CHART ................. 3-23-4 LUBRICATION CHART ....................................... 3-34-1 TROUBLESHOOTING CHART ........................... 4-1

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OPERATOR INSTRUCTIONS

WARNING

Do not operate this truck unless you have been trainedand authorized to do so and have read all warningsand instructions in operator's manual and on this truck.

Do not operate this truck until you have checked itscondition. Give special attention to Tires, Horn, Lights,Battery, Controller, Lift System, (including forks orattachments, chains, cables and limit switches),Brakes, Steering Mechanism, Guards and SafetyDevices.

Operate truck only from designated operating position.Never place any part of your body into the mast struc-ture or between the mast and the truck. Do not carrypassengers.

Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfaces thatcould cause truck to slide or overturn. Use specialcare when traveling without load as the risk of overturnmay be greater.

Travel with lifting mechanism as low as possible.Always look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with loador lifting mechanism trailing, except when travelingdownhill.

Use special care when operating on ramps—travelslowly, and do not angle or turn. Travel with liftingmechanism or load downhill.

Do not overload truck. Check capacity plate for loadweight and load center information.

When using forks, space forks as far apart as load willpermit. Before lifting, be sure load is centered, forksare completely under load, and load is as far back aspossible against load backrest.

Do not handle unstable or loosely stacked loads. Usespecial care when handling long, high or wide loads toavoid losing the load, striking bystanders, or tippingthe truck.

Do not handle loads which are higher than the loadbackrest or load backrest extension unless load issecured so that no part of it could fall backward.

Elevate forks or other lifting mechanism only to pick upor stack a load. Watch out for obstructions, especiallyoverhead.

Do not lift personnel except on a securely attachedspecially designed Work Platform. Use extreme carewhen lifting personnel. Make sure mast is vertical,place truck controls in neutral and apply brakes. Liftand lower smoothly. Remain in operating position orimmediate vicinity as long as personnel are on theWork Platform. Never transport personnel on forks orWork Platform.

Do not allow anyone to stand or pass under load or lift-ing mechanism.

When leaving truck, neutralize travel control. Fullylower lifting mechanism and set brake. When leavingtruck unattended, also shut off power.

PREPARATION FOR USE

Upon receipt, visually inspect the truck. If any damageis found, report it to the carrier and to your Big Joedealer immediately.

Remove cardboard banded to truck. Check lift truck forscratches and dents. Check to make sure that the liftchains are free of slack. Inspect for oil leaks and loosewiring connections. Make certain that all accessoriesand attachments that were ordered are supplied.

Before the lift truck is moved, the battery must bechecked, recharged if necessary, and connected.Refer to “Battery Care” in SECTION 3 for batterychecking instructions.

Refer to SECTION 2 for operating instructions ofthe brakes and lift control.

If you do not obtain the proper results, or if improperoperation occurs, refer to troubleshooting in SECTION4.

SECTION 1DESCRIPTION

1-1. INTRODUCTION.

This publication describes the Power Driven Counter-balanced Electronic Power Steering (PDCE) lift truckmanufactured by Big Joe Manufacturing Company,www.bigjoemfg.com. Included are operating instruc-tions, planned maintenance instructions, lubricationprocedures, corrective maintenance procedures and acomplete parts list with parts location illustrations.

Users shall comply with all requirements indicated inapplicable OSHA standards and current edition ofA.N.S.I. B56.1 part II. By following these requirementsand the recommendations contained in this manual,you will receive many years of dependable servicefrom your Big Joe lift truck.

The model number will be found on the name plate(Figure 1-1) along with the serial number, lifting capac-ity, and load center. Figure 1-2 shows the locations ofthe trucks main components and controls.

1-2. GENERAL DESCRIPTION.

The self-propelled PDCE truck, Figure 1-2, lifts andtransports payloads on adjustable forks that can betilted up and down. The PDCE 40 can lift up to 4000pounds.

The forward and reverse motion is controlled by aspeed controller switch in the control head. Stoppingand turning is controlled by the steering arm. Lift andLower is controlled by either a lever mounted on thechassis, optional pushbutton controls located on thecontrol arm, or a control box attached by a coiled cord.

Figure 1-1 Name Plate

The battery-powered lift truck is quiet and withoutexhaust fumes.

The reversible AC drive motor propels the lift truck inforward and reverse direction throughout the availablespeed range. The PDCE lift truck can be driven withforks raised or lowered; however, the speed isrestricted when the forks are raised above a presetlimit.

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1-3. SAFETY FEATURES.

The PDCE is designed and engineered to providesafety for operator and payload. Some of the safetyfeatures incorporated into the design are:

Dead-man brake to apply electrical brake and cut offdrive power when the steering arm is released.

Belly-button switch to reverse truck should the opera-tor accidentally pin himself against a wall or obstruc-tion.

High speed limit switch to restrict speed when lift car-riage is raised above the preset limit.

All control functions automatically return to “OFF”when released.

Externally accessible quick-disconnect battery plug.

Separately fused control circuits and power circuits.

Readily accessible HORN button.

Lift carriage backrest to help stabilize the load.

Pressure compensated flow control valve regulatesmaximum lowering speed.

High visibility color scheme of truck provides visualalert of trucks presence.

1-4. OPTIONS AND ACCESSORIES.

Big Joe offers many options and accessories for thePDCE lift truck such as:

Key switchRemote Lift ControlCold ConditioningHour Meter/Battery Capacity GaugeLift Limit SwitchLift Limit Override Switch

1-5. SAFETY SYMBOLS.

WARNING: This WARNING sign denotes a hazard. Itcalls attention to a procedure, practice orthe like, which if not correctly performedor adhered to could result in personalinjury.

CAUTION: This CAUTION sign denotes a hazard. Itcalls attention to a procedure, practice orthe like, which if not correctly performedor adhered to could result in personalinjury or damage to the equipment.

IMPORTANT:This heading calls attention to a proce-dure, which if not followed, may impedethe operation or normal flow of a servic-ing or repair procedure.

1-2 902998

Figure 1-2 PDCE Lift Truck

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NOTES

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SECTION 2OPERATION

2-1. GENERAL.

This section gives detailed operating instructions forthe PDCE lift truck. The instructions are divided intothe various phases of operations, such as operatingthe lift, driving, and stopping. Routine precautions areincluded for safe operation.

2-2. OPERATING PRECAUTIONS.

WARNING: Improper operation of the lift truck mayresult in operator injury, or load and/or lifttruck damage. Observe the followingprecautions when operating the PDCElift truck.

1. Do not operate this truck unless you have beentrained and authorized to do so, and have readand understand all warnings and instructions inthis manual and on the lift truck.

2. Do not operate this truck until the periodic inspec-tion or service has been completed. See Table 3-1.

3. Do not exceed the rated capacity (see nameplate). Overloading may result in damage to thehydraulic system and structural components.

4. Do not handle unstable or loosely stacked loads.Use special care when handling long, high, orwide loads to avoid tipping, loss of load, or strikingbystanders.

5. Center and carry the load as far back as possibletoward the lift carriage back rest. Do not pick uploads on the tips of forks. The center-of-gravity ofthe load must not exceed the load center listed onthe name plate. See Figure 2-1 for load centerlimitations.

6. Pick up loads on both forks. Do not pick up loadson only one fork.

7. When traveling, always lower the load as far aspossible.

8. When stacking pallets in racks and it is necessaryto move the load in the raised position, use cau-tion. Operate truck smoothly.

9. Check for obstructions when raising or loweringthe lift carriage.

10. Apply the brake gently except in cases of emer-gency.

11. Observe applicable traffic regulations. Yield rightof way to pedestrians. Slow down and sound hornat cross aisles and wherever vision is obstructed.

12. Operate truck only from a walking position. Neverplace any part of your body between the mastuprights. Do not carry passengers.

13. Do not allow anyone to stand or pass under loador lifting mechanism.

Figure 2-1 Load Center

SAFE UNSAFE

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2-3. BEFORE OPERATION

Table 2-1 covers important inspection points on PDCElift truck which should be checked prior to operation.Depending on use, some trucks may require additionalchecks.

Figure 2-2 shows a sample format for a OperatorChecklist, which can be modified as necessary to fityour operation.

WARNING: Periodic maintenance of this truck by aQUALIFIED TECHNICIAN is required.

CAUTION: A QUALIFIED SERVICE TECHNICIANshould check the truck monthly forproper lubrication, proper fluid levels,brake maintenance, motor maintenanceand other areas specified in the SEC-TION 3.

WARNING: If the truck is found to be unsafe and inneed of repair, or contributes to anunsafe condition, report it immediately tothe designated authority. Do not operateit until it has been restored to a safeoperating condition. Do not make anyunauthorized repairs or adjustments. Allservice must be performed by a qualifiedmaintenance technician.

Table 2-1 Operator Checks

ITEM PROCEDURETransmission and hydraulic systems.

Check for signs of fluid leakage.

Forks Check for cracks and damage; and, that they are properly secured.

Chains, cables and hoses

Check that they are in place, secured correctly, functioning properly and free of binding or damage.

Guards and load backrest

Check that safety guards are in place, properly secured and not damaged.

Safety signs Check that warning labels, nameplate, etc., are in good con-dition and legible.

Horn Check that horn sounds when operated.

Steering Check for binding or looseness in control arm when steering.

Travel controls Check that speed controls on control head operate in all speed ranges in forward and reverse and that belly button switch func-tions.

Wheels Check drive wheel for cracks or damage. Move truck to check load wheels for freedom of rota-tion.

Hydraulic con-trols

Check operation of lift and lower to their maximum positions.

Brake Check that brake actuates when control arm is raised to upright position, and when lowered to horizontal position.

Deadman/Park-ing brake

Check that control arm raises to upright position when released and brake applies.

Battery discon-nect

Check that battery can be disconnected and reconnected. Check for connector damage.

Battery charge Check that battery capacity meter (if equipped).

High speed limitswitch

Allow for enough space to oper-ate truck in high speed. Elevate forks approximately two feet, then test drive truck to check if high speed is cut out.

ITEM PROCEDURE

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Figure 2-2 Sample of Operator Check List

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Electric TruckDaily Operator Check-Off List

Date

Big Joe Manufacturing Company

Operator

Truck No. Model No.

Dept.

Check

Tires

Lights

Horn

Lift Lower Control

Tilt Control

Attachment Operation

Drive Control

Steering

Service Brakes

Parking Brake

Hydraulic Leaks, Cylinders,

Valves, Hoses, Etc.

Need MaintenanceO.K. ( )

Shift

Hour Meter

Reading Drive Hoist

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2-4. INSTRUMENTS AND CONTROLS

2-4.1. Steering Arm and Control Head.

The control arm and control head (See Figure 2-3)provide controls for steering, forward and reversespeed control, braking, and horn. Control heads onsome models have pushbuttons for raising and lower-ing the forks. Table 2-2 lists optional control head.Control head on all models have a “belly-button”reversing switch which reverses the direction of thetruck upon contact with the operator.

Table 2-2 Control Heads

Figure 2-3 Control Head

Type Part Numbers.Standard,

Rubber Grips506124-05

Standard, Rubber Grips, Cold Conditioning

506124-06

Remote Lift & Lower,Rubber Grips

506124-07

Remote Lift and Lower in Handle

506124-08

Standard, Aluminum Grips

506626-01

Standard, Aluminum Grips, Cold Conditioning

506626-02

Remote Lift & Lower,Aluminum Grips

506626-03

Remote Lift & Lower,Aluminum GripsCold Conditioning

506626-04

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2-4.2. Lift/Lower and Tilt Control.

All models come standard with a lift/lower control leverand a tilt control lever mounted near the steering arm.See Figure 2-4

2-4.3. Battery Disconnect.

A battery disconnect is mounted near the rear of thebattery compartment. Pulling the disconnect removesall power from truck circuits in the event of an emer-gency. See Figure 2-4

2-4.4. Optional Features.

The optional remote lift/lower control (if equipped)allows the operator to raise and lower the forks whilestanding away from the control head. See Figure 2-5.

Other options are the hourmeter/battery capacitygauge and key switch, which mount on the panel nearthe control handle. The hourmeter/battery capacitygauge displays battery state-of-charge, operatinghours and Maintenance Status. The key switch pro-vides added security to the truck, preventing unautho-rized personnel from operating the machine.

2-5. OPERATION

2-5.1. Forward and Reverse Travel and Speed Control.

All directional and speed controls are located on thecontrol head. See Figure 2-3.

Forward and reverse are controlled by rotating thespeed control lever. The lever is spring loaded toreturn to neutral when released. Further rotation ineither direction will progress the truck from slow tomaximum travel speed.

To change directions or to stop the truck, rotate thespeed control lever in the opposite direction. The truckwill come to a stop and then, unless the controls arereturned to the center neutral position, accelerate inthe opposite direction.

2-5.2. Steering.

The “On-Demand” steering allows operators tosmoothly steer the PDCE with less then 5 lbs of steer-ing force. This innovation safely increases productivityby allowing the operator to effortlessly maneuver thetruck.

Moving the control head (which connects to the steer-ing arm) right or left will turn the truck right or left.When maneuvering around corners, make squareturns and be sure there is adequate clearance.

Figure 2-4 Lift/Lower Lever

Figure 2-5 Optional Remote Lift/Lower Control

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2-5.3. Stopping.

Stop the truck as gradually as possible. Unnecessaryrapid stopping could be hazardous. Load couldbecome unstable.

There are three possible ways to stop the truck:

1. Plugging: This electrical braking function con-sists of rotating the speed control lever in theopposite direction of travel and then releasing itwhen the truck stops. Plugging is a convenientway to stop the truck during normal operation. Ifthe control is not released, the truck will acceler-ate in the opposite direction.

2. Control arm in horizontal position (See Figure2-6): Lowering the control arm to the horizontalposition applies the brake.

3. Control arm in vertical position (See Figure 2-6): Raising the control arm to near vertical posi-

tion applies the brake. This position serves as aparking brake. As a safety precaution, the controlarm is spring loaded to return to the vertical posi-tion in the event the driver releases the controlhead during operation. This is known as deadmanbraking.

2-5.4. Parking.

When parking the truck, do not obstruct traffic lanes oraisles.

1. Park the truck in its designated parking area.

2. Raise the control arm until vertical to apply theparking brake.

3. Fully lower forks.

4. Turn key switch (if so equipped) to off position.Remove key for added security.

5. Pull out battery disconnect.

Figure 2-6 Control Arm Braking Positions

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2-5.5. Battery Charging

Refer to Document 245 for battery safety andmaintenance.

NOTE: Battery charging instructions are contained inSECTION 3.

2-5.6. Load Handling.

WARNING: Handle only loads arranged for stability,and always use caution. Raise and lowerthe load smoothly to prevent the loadfrom falling.

WARNING: Always be sure the load and load centerare within the capacity of the truck. If indoubt, check the nameplate.

1. Approach the load slowly.

2. Stop the truck when the forks are just in front ofthe load.

3. Adjust the forks to the maximum practical width tosupport the load to be lifted.

4. Raise or lower the forks until they are properlyaligned with the pallet openings.

5. Move the truck slowly into position so that theforks are centered about the load.

6. Make sure the load is against the backrest andthen raise the forks until the pallet clears the rack.

7. Move the truck away from the rack until the loadclears the rack and then lower the forks.

8. Lead the truck by the control head with the loadtrailing except when in confined areas. Rampsshould be traveled with operator uphill of truckwhen empty, or operator downhill of truck whenload on forks.

9. Always look in the direction of travel. Move slowlyand check clearances when approaching obstruc-tions.

10. Do not make sudden starts and stops. Operatetruck smoothly and gradually.

11. Travel slowly and squarely around corners.Remember that the trailing load wheels do not fol-low the turn path of the drive wheel. Instead theytend to cut the corner.

12. Line up the truck with the unloading area.

13. Stop the truck and raise or lower the forks until thepallet is in position with the unloading area.

14. Check the load alignment with surroundingobjects.

15. Be careful not to damage or move adjacent loadsand objects.

16. Slowly move into position.

17. Lower the forks until the load is resting on its own.Be sure there is no downward force of the forkson the rack or floor.

18. Move the truck back until the forks are clear of thepallet.

19. If forks are elevated, lower to travel position.

2-5.7. Moving a Disabled Truck

Do not attempt to move a disabled truck. Notify yoursupervisor or proper authority.

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NOTES

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SECTION 3PLANNED MAINTENANCE

3-1. GENERAL.

Planned maintenance consists of periodic visual andoperational checks, parts inspection, lubrication, andscheduled maintenance designed to prevent or dis-cover malfunctions and defective parts. The operatorperforms the checks in SECTION 2, and refers anyrequired servicing to a qualified maintenance techni-cian who performs the scheduled maintenance andany required servicing.

3-2. MONTHLY AND QUARTERLY CHECKS.

Table 3-1 is an inspection and service chart based onnormal usage of equipment eight hours per day, fivedays per week. If the lift truck is used in excess of fortyhours per week, the frequency of inspection and ser-vice should be increased accordingly. These proce-dures must be performed by a qualified servicetechnician or your Big Joe service representative.

3-3. BATTERY CARE.

3-3.1. General.

The life of the battery can be extended by giving itproper care. Perform a daily check of the batterywhether or not the equipment is in daily use. DO NOTovercharge the battery or battery life will be shortened.DO NOT allow battery to become completely dis-charged (specific gravity 1.150 or less). This will alsogreatly shorten battery life.

3-3.2. Battery Servicing.

Refer to Document 245 for battery safety andmaintenance.

The battery cells are accessed by opening the topcover of the battery. Use the following procedure:

1. Obtain a battery hydrometer.

NOTE: These can be obtained from a local hardwarestore or automotive shop.

2. Use the hydrometer to check specific gravity ofeach cell

NOTE: Battery specific gravity readings should agreewithin ± 0.025 from cell to cell. If variation isgreater, the battery may have to be repairedor replaced.

CAUTION: Be sure that no cell plates are exposed(not covered by fluid) before charging.Add distilled water sufficient to just covertop of cell plates.

CAUTION: Use distilled water. Impurities in tapwater will damage battery plates.

3. Charge battery as necessary.

NOTE: A fully charged battery has a specific gravityof 1.260 to 1.275.

4. After charging, check water level in each cellagain. Water level must cover plates but not behigher than the base of the battery cell filler neck.

3-4. LUBRICATION.

Refer to Table 3-2 for the recommended types ofgrease and oil, and Table 3-3 for hydraulic oil capaci-ties. Table 3-4 in conjunction with Figure 3-1 identifiesthe items requiring lubrication.

3-5. LIFT CHAIN MAINTENANCE

Fully raise and lower lift carriage while observingchains they move over all chain sheaves. Ensurechain is aligned and tracking properly and all links arepivoting freely. With carriage fully lowered, spray orbrush on a film of ASAE 30 or 40 engine oil.

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Table 3-1 Inspection and Service Chart

Table 3-2 Recommended Lubricants and OIls Table 3-3 Hydraulic Oil Capacity Chart

VISUAL CHECKSINTERVAL INSPECTION OR SERVICE

Monthly Check condition of drive motor commutator, brushes and springsMonthly Check condition of pump motor commutator, brushes and springsMonthly Check electrical brake for proper operationMonthly Check load wheels for wearMonthly Check drive wheel for wearMonthly Inspect wiring for loose connections and damaged insulationMonthly Check deadman brake switch for proper operationMonthly Check lift chain tension, lubrication & operation (see paragraph 3-5.)Monthly Lubricate Unit (See Table 3-4)Quarterly Check lift cylinder for leakageQuarterly Check for excessive jerking of steering arm when stopping or startingSemi-annually Replace hydraulic filter assemblySemi-annually Inspect for chain wear (See SECTION 8)

No. 1 Transmission oil—EP SAE 80W-90Transmission oil—EP SAE 10W30 (Note)Transmission oil capacity is 3 pints.

No. 2 Grease—Lithium base, general purpose.No. 3 Hydraulic oil-Heavy duty with a viscosity

of 150 SUS (in temperatures below 32 °F use 100 SUS) foam suppressing agent and rust and oxidation inhibitors. See Table 3-3 for oil capacity.Big Joe Part No. 900855 (1 gallon)900893 (1 quart)055784 (Note)

No. 4 SAE 30 or 40 engine oilNOTE: USED ON COLD CONDITIONED TRUCKS

LIFT HEIGHT OIL CAPACITY60 in 10 qts106 in 10 qts130 in 10 qts154 in 10 qts168 in 10 qts

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Figure 3-1 Lubrication Diagram

Table 3-4 Lubrication Chart

Figure 3-1REF

ITEM METHOD OF APPLICATION

TYPE (Table 3-2)

NOTES

1 Transmission Can No. 1 Fill to hex plug (fill level plug) level. Remove vent and fill through vent hole.

2 Chain sheaves Gun No. 2 Pressure lubricate.3 Free Lift Slide bar

(Telescopic Trucks)Brush No. 2 Clean off old grease and apply a thin

coat the full length of slide bar where ram head touches.

4 Outer and inner masts

Brush No. 2 Clean off old grease and apply a thin coat the full length of mast where rollers touch.

5 LIft Chains Brush or Spray No. 4 See paragraph 3-5.6 Lift carriage rollers Gun No. 2 Pressure lubricate.7 Tilt cylinder mounts Gun No. 2 Pressure lubricate both ends of each

cylinder.

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NOTES

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SECTION 4TROUBLESHOOTING

4-1. GENERAL

Table 4-1 serves as a guide to determine possiblecauses of trouble. The table is divided into five maincategories: Truck dead: trouble with travel: trouble withbraking: trouble with lifting or lowering, and Miscella-neous malfunctions. Refer to electrical wiring diagram(Figure 4-1) as a supplement to the troubleshootingchart or when tracing an electrical circuit.

Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

TRUCK DEAD

Truck will not run forward or in reverse, nor will lift system operate

a. 300-Amp fuse blown. Check fuse and replace if defective.

b. Battery dead or disconnected. Check battery quick-disconnect plug. Check battery (See SECTION 3).

c. Defective key switch. Check and replace if required.

d. Defective wiring. Check for open circuit. Repair as required.

TROUBLE WITH TRAVEL Check all wiring. A loose connec-tion may be the cause of malfunc-tion.

Tighten all loose connections before fur-ther troubleshooting.

Truck does not run forward or reverse. Everything else is normal.

a. 15-Amp control circuit fuse blown.

Check fuse and replace if defective.

b. Defective dead-man brake switch.

Check and replace if required.

c. Main wire harness cut. Replace.

d. Belly button switch defective. Replace.

Truck runs forward, but not in reverse.

a. Defective speed control switch or controller.

Check for positive DC voltage at number 2-wire of lower control cable at electrical panel. If not present when steering arm is in operating position and speed control is in reverse, speed control switch is defec-tive. If voltage is present, controller is defective.

b. Belly button switch out of adjustment or defective.

Adjust or replace.

Truck runs in reverse, but not in forward.

Defective speed control switch or defective contactor.

Check for positive DC voltage at number 1 wire of lower control cable at electrical panel. If not present when steering arm is in operating position and speed control is pressed for forward travel, speed control switch is defective. If voltage is present, contactor is defective.

902998 4-1

Truck runs forward and in reverse at lower speeds; will not run at higher speeds.

a. Defective travel speed limit switch.

Adjust or replace.

b. Defective potentiometer in control head.

Check for variable resistance at the potentiometer when direction control is activated. If not noted, replace potentiometer.

TROUBLE WITH BRAKING

Truck does not slow with brake, or brake does not engage. Electrical brake does not stop truck properly.

a. Defective brake/deadman switch

Check brake/deadman switch for continu-ity. If none found when the control arm is in the brake position, replace switch.

b. Defective brake solenoid. Replace brake.

TROUBLE WITH LIFTING OR LOWERING

Oil level too low. Check hydraulic oil level. Fill hydraulic res-ervoir so that oil is shown full on dipstick (approximately 2 inches from top of reser-voir) with the lift carriage fully lowered, before further troubleshooting. Tighten all electrical connections.

Lift carriage does not rise; everything else is normal.

a. Defect in electrical system. a. If pump motor does not run when LIFT control is in UP position, defect is in pump solenoids, or pump motor. Check for positive DC voltage at pump motor to locate defect. Repair or replace defective part.

b. Check switch on control valve. Adjust or replace as necessary.

b. Defect in hydraulic system. a. Check for pinched hoses. Check pump for proper operation. Replace if neces-sary.

b. Check flow control valve near base of lift cylinder. Check for defect in lift cyl-inder.

Lift carriage does not lower; everything else is normal.

Control valve defective or defect in hydraulic system.

Check control valve for proper action. Check for obstruction in the hydraulic line. Repair as required.

Forks creep downward under load; everything else is nor-mal.

Leak in hydraulic system, packing, control valve, or pump.

Look for loose fittings in the hydraulic line, pump for leakage back into the reservoir and oil on top of packing. Repair fittings or replace pump as required. Replace pres-sure relief valve.

Oil sprays or flows from the top of the lift cylinder.

Defective packing in lift cylinder. Overhaul the lift cylinder and install new packing, seal, and wiper ring.

Oil foaming in vent for hydrau-lic reservoir.

Leak in the suction line between the pump and the reservoir.

Check oil filter. Replace if necessary. Tighten fitting. Inspect line and replace if necessary.

Oil splashes out of vent when lowering forks.

Oil level too high. Drain, then refill reservoir when lift car-riage is in the lowest position.


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Squealing sounds when forks are raised.

a. Oil level too low. Add oil to reservoir.

b. Dry channels in mast. Apply grease.

c. Defective bearing. Replace bearing.

Forks do not lift to top. Pump motor runs.

a. Oil level too low. Add oil to reservoir.

b. Load heavier than capacity. Refer to nameplate for maximum load capacity.

c. Defective pump or motor. Replace.

Control valve spring- centered handle does not return to neu-tral.

a. Broken springs. Replace springs.

b. Foreign particles. Clean system and valve.

c. Misalignment of operating link-age.

Check linkage for binding condition.

Load drops when LIFT control is moved from neutral to UP position.

a. Dirt or foreign particles lodged between check valve poppet and seat.

Disassemble, clean and reassemble.

b. Scored check ball. Replace check ball.

c. Defective check ball seat in valve body.

Lap new check ball body seat.

No motion, slow or jerky action of hydraulic system.

a. Load heavier than capacity. Refer to nameplate for maximum lift capacity.

b. Defective lift cylinder. Rebuild or replace.

MISCELLANEOUS

Steering arm does not return to the upright position.

a. Return spring improperly adjusted.

Readjust spring tension (see paragraph 5-6.1.).

b. Binding brake linkage or elec-trical cable.

Check and free the binding item.

c. Broken spring Replace.

Truck moves forward in low speed when arm is pulled down.

a. Belly-button reversing switch defective.

Check for short, and repair or replace as necessary.

b. Forward contactor stuck closed.

Repair or replace.

Steering arm jerks excessively when starting or stopping the truck.

a. Worn steering adapter plate. Replace.

b. Drive tire worn or mounted incorrectly.

Repair or replace.


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Figure 4-1. Electrical Wiring Diagram (Sheet 1)

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Figure 4-1. Electrical Wiring Diagram (Sheet 2)

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NOTES

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SECTION 5CONTROL ARM AND CONTROL HEAD SERVICING.

5-1. GENERAL.

The following procedures cover adjustments, replace-ment, and repair of the control arm, control head, andrelated assemblies and components. The proceduresare independent of each other unless specificallyreferenced.

5-2. COLD CONDITIONING.

The cold conditioning version of the truck differs fromthe standard model where necessary to improve per-formance in cold temperatures. Heating resistors areprovided for the control head switches, and cold resis-tant versions of other switches are used. Special coldtemperature lubricants are also necessary for thisapplication.

Figure 4-1 shows the wiring diagram of the cold condi-tioning circuit. Location of electrical parts in the controlhead and resistor wiring of cold conditioning equip-ment is illustrated in Figure 12-3.

CAUTION: Cold conditioning heating resistors con-sume power when energized, whethertruck is used or not. To avoid powerwaste during lengthy storage periods,remove truck from cold temperatures.

5-3. BELLY-BUTTON SWITCH ADJUSTMENT.

NOTE: All electrical connections should be taggedwith identifying labels before disconnecting.

1. Disconnect battery.

CAUTION: While removing the belly-button casting,two springs (needed for reassembly) willfall free.

2. Being careful to catch and retain the belly-buttonsprings (4, Figure 5-2) that may fall from the con-trol head (50) as the belly-button casting (1) isremoved, drive out the roll pins (2) that secure thebelly-button casting. Drive the roll pin from left toright. The roll pin is only tight on the left side.

CAUTION: A misaligned switch may actuate (click)early or late in travel, or fail to operate.

WARNING: Test switch in an open area to avoidbeing accidentally pinned.

3. Bend actuator lever of belly-button switch (Figure5-1) to adjust gap so that switch clicks half waythrough travel of casting.

4. Reinstall casting, making certain all parts are backin place.

5. Check operation of the belly-button switch bypressing the belly-button casting while listeningfor the “click” that indicates that the switch hasactuated.

NOTE: The click should be heard when the belly-but-ton casting has moved about 50 percent of itsnormal travel distance. If the click is heard atthe beginning of travel, the switch may actu-ate at inappropriate times. If the click is heardnear the end of travel, the switch could beunreliable and may not actuate in someinstances.

6. Repeat steps 2. through 5. until pressing thebelly-button casting actuates the switch properly.

7. Reconnect battery and electrical connections.

WARNING: Testing of belly-button switch in opera-tion should be limited to areas clear ofobstacles against which an operatorcould be pinned. Use first speed,reverse.

Figure 5-1 Belly-Button Switch Adjustment

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Figure 5-2 Control Head Assembly

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5-4. POTENTIOMETER TESTING AND ADJUST-MENT

1. Disconnect the battery

2. Remove screws (12, Figure 5-2) and access cov-ers (13 and 53).

3. Check gap between rollers on directionalswitches (32) and surface of cam (34). If required,adjust position of bracket (27) to obtain a 0.03-0.06 inch clearance.

4. Disconnect the electrical control cable from theelectrical control panel. Set an ohmmeter to theRXIK (1000) scale and connect across pin con-tacts of wires 13 and 16 at the control cable pinhousing.

5. Slowly press the control lever (43) in the forwarddirection until a click indicating forward switch clo-sure is heard. Ohmmeter should indicate 4550ohms (± 250 ohms).

6. If incorrect reading is obtained, use access hole,in the side of the control head (Figure 5-3) to gainaccess to the potentiometer. (25, Figure 5-2).Insert a screwdriver blade into the slot on theback side of the potentiometer (Figure 5-3) andturn slightly. Vary the amount and direction ofscrewdriver rotation until the specified value isachieved.

7. Repeat step 5. while pressing control lever inreverse direction. Meter readings should be thesame as for the forward direction (± 200 ohms). Ifmeter readings are not the same, adjust positionof bracket (28, Figure 5-2) as necessary to obtainthe same values. Adjust the potentiometer again ifnecessary.

8. Reassemble the control head.

5-5. CONTROL HEAD SWITCH REPLACEMENT.

5-5.1. Belly-Button Switch



2. Remove belly-button casting (1, Figure 5-2) asdescribed in paragraph 5-3.

3. Remove nuts (5) and screws (8) to release belly-button switch (7) and insulator (6).

4. Tag and disconnect electrical wires from belly-but-ton switch (7).

5. Connect electrical wires to new belly-buttonswitch (7), as noted during removal.

Figure 5-3. Control Head Potentiometer Adjustment

6. Install insulator (6) and belly-button switch (7) andsecure with screws (8) and nuts (13).

7. Reconnect batteries.

8. Adjust belly-button switch (paragraph 5-3.).

5-5.2.Lift Switch, Lower Switch or Horn Switch



2. Remove top cover (13, Figure 5-2) from controlhead by removing four screws (12).

3. Remove button cover (53) from control head byremoving four screws (12).

4. Remove screws (11 and 49) to release switchplate (57).

5. Remove screws (58) to remove lift or lower switch(54 or 55). ORRemove nut and washer from back of horn switch(60).

6. Tag and disconnect electrical wires from defectiveswitch.

7. Connect wires to new switch, as noted duringremoval.

8. To install lift or lower switch (54 or 55), position onback of switch plate (57) and secure with screws(58). ORTo install horn switch (60), position on front ofswitch plate (57) and secure with it’s washer andnut.

ControlHead

AdjustmentAccess Hole

PotentiometerAdjustment Slot

I-7008

902998 5-3

9. Install switch plate (57) and secure with screw (11and 49).

10. Install top cover (13) and secure with screws (12).

11. Install bottom cover (53) and secure with screws(12).

12. Reconnect batteries.

5-5.3.Speed Control Switches and Return Spring



2. Remove four screws (17, Figure 5-4) securingcontrol head (23) to control arm (22).

3. Disconnect control arm control cable from thecontrol head.

4. Remove four screws (12, Figure 5-2) securing topcover (13) to control head.

5. Disconnect speed control switches (32).

6. Remove four screws (36) securing handle guard(37) to control head.

7. Remove two socket head screws (39) and caps(38) from handle guard (37).

8. Remove handle guard with two brackets (28 and27) and speed control switches (32) attached.

9. Remove roll pin (42) from right hand handle grip(41).

10. Remove right hand handle grip from shaft (40).

11. Remove set screw (44) from right hand controllever (43).

12. Remove right hand control lever from tube (46).

13. Observing through top cover opening, slide shaft(40) with tube (46) out left hand side of controlhead just enough to clear return spring (22).

14. Disengage return spring from spiral pin (23) andremove return spring.

15. Place new return spring in position, engage withspiral pin, and slide shaft (40) with tube (46) backthrough return spring and out right hand side ofcontrol head.

16. Install right hand control lever (43) onto tube (46),and secure with set screw (44).

17. Install right hand handle grip (41) onto shaft (40),align roll pin hole in handle grip with roll pin hole inshaft, and install roll pin.

18. Install handle guard (37), with two brackets (28and 27) and switches (32) attached, and securewith two caps (38) and screws (39).

19. Install four screws (36) through handle guard andinto control head.

20. Reconnect speed control switches (32).

21. Install top cover (13) with four screws (12).

22. Reconnect control arm control cable to the controlhead.

23. Install control head (23, Figure 5-4) onto controlarm (22) with four socket head screws (17).

24. Reconnect battery.

5-5.4.Potentiometer



2. Remove four screws (17, Figure 5-4) securingcontrol head (23) to control arm (22.

3. Disconnect control arm control cable from thecontrol head.

4. Remove four screws (12, Figure 5-2) securing topcover (13) to control head.

5. Disconnect speed control switches (32).

6. Remove four screws (36) securing handle guard(37) to control head.

7. Remove two socket head screws (39) and caps(38) from handle guard (37).

8. Remove handle guard with two brackets (28 and27) and speed control switches (32) attached.

9. Remove potentiometer (25) from bracket (29).

10. Install potentiometer (25) on bracket (29).

11. Install handle guard (37), with two brackets (28and 27) and switches (32) attached, and securewith two caps (38) and screws (39).

12. Install four screws (36) through handle guard andinto control head.

13. Reconnect speed control switches (32).

14. Install top cover (13) with four screws (12).

15. Reconnect control arm control cable to the controlhead.

16. Install control head (23, Figure 5-4) onto controlarm (22) with four socket head screws (17).


5-4 902998

Figure 5-4 Control Arm

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902998 5-5

5-6. STEERING ARM.

5-6.1.Return Spring Adjustment

The tension on the control arm return spring shouldallow the control arm to return gently to the uprightposition. Excessive tension on the control arm returnspring will cause the steering arm to snap up and maycause damage to the electrical cable, or the springitself. If the steering arm does not return fully, check forbinding. Refer to Figure 5-4 and proceed as follows toadjust the steering arm return spring tension.

1. Disconnect the battery.

2. Hold the control arm (22, Figure 5-4) in the uprightposition and make sure the arm cannot fall.

3. Insert a 5/16 allen wrench through hole in bottomof control arm and loosen screw (25). The springtube (28) will rotate counterclockwise when screwis loosened.

4. With a pair of vise grip pliers, grip the flat surfacesof the spring tube assembly (28) and rotate clock-wise 180 degrees.

5. Hold spring tube assembly in rotated position andtighten screw (25) to secure.

6. Check the spring action by lowering the controlarm and returning it to the upright position two orthree times.

7. If necessary, repeat steps 2. through 6., increas-ing or decreasing amount of rotation of the springtube assembly until steering arm returns gently tofull upright position.


5-6.2.Return Spring Replacement.

NOTE: Refer to Figure 5-4 for the following proce-dure.

NOTE: The control arm return spring is replacedwhile the control arm is in the upright position.


NOTE: The control arm has a tendency to fall down-ward when the tension on the return spring isreleased.

2. Hold control arm (22, Figure 5-4) in upright posi-tion and make sure the arm cannot fall.

3. With a piece of chalk or crayon, draw a straightline from center of spring tube assembly (28) intopivot cap (4), marking radial position of tube, tofacilitate reinstallation.

4. Insert a 5/16 allen wrench through hole in bottomof control arm and loosen screw (25).

CAUTION: Unless properly supported, control armwill drop out of pivot cap when springtube is removed.

5. Put a block under control arm at pivot cap.

6. With a pair of vise-grip pliers, grip the flat surfacesof spring tube assembly (28), and slowly pull itfree from the control arm, pivot cap and tubeclamp (30).

NOTE: Control arm return spring (27) will remaininside the spring tube assembly (28).

7. Remove control arm return spring (27) fromspring tube assembly (28).

8. Lubricate the ends and outer surface of the newcontrol arm return spring (27) with a lithium basegeneral purpose grease.

9. Insert spring into spring tube assembly and pressin, making sure that one spring loop eye fits overthe roll pin at the closed end of the spring tubeassembly.

10. Slide spring tube assembly into pivot cap (4) andcontrol arm (22) through tube clamp (30) andthrough loop of electrical cable.

11. Align radial position of spring tube assembly inaccordance with line drawn in step 3. Slowlyrotate spring tube assembly a few degrees eachway until the control arm return spring snaps intoplace over spring pins (8 and 9) then tightenscrew (25).

12. Apply engine lubricating oil (No. 2) to the controlarm elbow.

13. Remove block from under control arm.

14. Adjust tension on control arm return spring asexplained in paragraph 5-6.


5-7. ELECTRICAL CONTROL CABLE REPLACE-MENT.


2. Remove the compartment cover (2, Figure 5-6).

NOTE: When removing control head in the followingstep, be sure to hold it in place until cable isdisconnected.

3. Remove four screws (17, Figure 5-4) that securecontrol head (23) to control arm (22).

5-6 902998

4. Disconnect connector (8, Figure 5-7), and setaside control head.

5. Use Amp Extraction Tool, Part Number 900750to push out and disconnect wire pins from con-nector (8).

6. Remove cable clamps (9 and 10) and loosen loopof cable (7) that surrounds the spring tube assem-bly.

7. Remove pivot cap cover (12, Figure 5-6).

8. Remove base access cover (2).

9. Disconnect connector (3, Figure 5-7) from theswitch harness.

10. Disconnect connectors (4 and 5) from the electricbrake leads.

11. Pull disconnected end of old cable down throughcontrol arm and remove from loop of cable (7)from the spring tube assembly.

12. If equipped with cold conditioning, disconnectwire number 12 of cable (7).

13. Disconnect cable (7) from connector (12).

14. Use Amp Extraction Tool, Part Number 900750to push out wire pins of switch harness (13) fromconnector on cable (7).

15. Install wires of switch harness (13) into connectoron cable (7). See Figure 5-5.

16. Connect the new cable (7) to the connector (12).

17. If equipped with cold conditioning, reconnect wirenumber 12 of cable (7).

18. Loop of cable (7) around the spring tube assem-bly as shown in Figure 5-7.

19. Eliminate cable slack below loop and secure withcable clamp (10).

CAUTION: Improper cable loop adjustment whileperforming the following step will dam-age the cable. If too tight, the cable willtear when the control arm is in the upposition. If too loose, the cable willbuckle or be pinched when the controlarm is in the down position.

Figure 5-5 Switch Harness Connection

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902998 5-7

20. Route the new cable up into the steering arm (10).

NOTE: When performing step 21., be sure to leaveenough cable to attach to the control head.

21. Secure cable (7) with cable clamp (9).

22. Plug the wire pins into their corresponding recep-tacles in the connector (8).

23. Position the control head close enough to thecontrol arm to reach the connector (8).

24. Reconnect the connector (8) to the correspondingconnector in the control head.

25. Secure the control head to the control arm withthe four screws (17, Figure 5-4).

26. Disconnect connector (3, Figure 5-7) from theswitch harness.

27. Disconnect connectors (4 and 5) from the electricbrake leads.


Figure 5-6 Base and Frame

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Figure 5-7 Electrical Control Cable Replacement

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NOTES

5-10 902998

SECTION 6BRAKE SERVICING

6-1. DEADMAN SWITCH ADJUSTMENT

If the electrical brake does not engage when the steer-ing arm is raised or lowered into the lightly shadedarea in Figure 6-1, proceed as follows:

1. Disconnect battery connection.

2. Block the wheels to prevent the truck from rolling.


NOTE: When standing at the control head, the Dead-man Switch is located on the right hand sideof the pivot cap (4, Figure 6-3).

4. Loosen three screws (5) and adjust deadmancam (21) so that switch clicks when the controlarm is raised and lowered to the shaded areasshown in Figure 6-1.

5. Tighten screws (5, Figure 6-3).

6. Reinstall pivot cap cover (12, Figure 6-2).

7. Reconnect the battery.

8. Remove wheel blocking and check truck forproper operation before returning to service.

6-2. DEADMAN SWITCH REPLACEMENT

1. Disconnect battery connections.

2. Block the wheels to prevent the truck from rolling.


NOTE: When standing at the control head, the Dead-man Switch is located on the right hand sideof the pivot cap (4, Figure 6-3).

IMPORTANT:Do not loosen the mounting screws forthe deadman actuation cam (21).

4. Remove the switch mounting bracket screws (5)and remove the switch mounting bracket (32) withswitch (33).

5. Tag and disconnect electrical wires from dead-man switch (33).

6. Remove deadman switch (33) from the mountingbracket and install new switch onto mountingbracket.

7. Reconnect wiring to new deadman switch (33) asnoted during removal.

8. Reinstall mounting bracket (32) in pivot cap (4).

9. Reinstall pivot cap cover (12, Figure 6-2).

10. Reconnect the battery.

11. Remove wheel blocking and check truck forproper operation before returning to service.

Figure 6-1 Brake Engage/Disengage

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NOTES

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SECTION 7TRANSMISSION, DRIVE WHEEL AND LOAD WHEEL SERVICING

7-1. DRIVE WHEEL REMOVAL


2. Raise the rear of the truck using jacks or othersuitable means so that drive wheel is off the floor.

3. Remove the five lug nuts and washers (23, Figure 7-2).

4. Remove wheel assembly (22).

5. Position the new drive wheel on the lugs andsecure with washers and lug nuts (23).

6. Torque nuts (23) to 90 ft lbf.

7-2. TRANSMISSION, MOTOR AND BRAKE REMOVAL


2. Raise the rear of the truck using jacks or othersuitable means so that drvie wheel is off the floor.


4. Remove motor cover (2).

5. Tag and disconnect control arm cable (17, Figure7-5) from lower control cable (9).

6. Remove two screw (2, Figure 7-1) and removebracket (2) with finger plates and stop attached.

7. Attach a hoist to control head (10, Figure 7-3).

8. Rotate the pivot cap until bearings (3) are alignedwith groves (4).

9. Lift off control arm and pivot cap.

10. Remove two screws (4, Figure 7-2) and removetorque sensor (14) from bracket (16). Set the sen-sor aside.

11. Disconnect the harness (36, Figure 7-5) from theAC drive motor (9, Figure 7-2).

12. Remove three screws (8) and three washers (3).

13. Remove AC drive motor (9).

14. Remove two screws (13, Figure 7-5) to freeanchor block (14) .

15. Remove clamp (3) securing the cables to the ACdrive.

16. Tag and disconnect cables (6, 7, and 8) from thedrive motor.

17. Attach a hoist to AC drive (9, Figure 7-3).

18. Remove twelve screws (14) and lift off AC drive(9).

Figure 7-1 Pivot Cap Removal

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902998 7-1

Figure 7-2 AC Drive and Steering System

R6557

7-2 902998


7-3. TRANSMISSION, MOTOR AND BRAKE INSTALLATION

1. Attach a hoist to AC drive (9, Figure 7-3) and lift itinto position.

2. Secure AC drive (9) with twelve screws (14).

3. Reconnect cables (6, 7, and 8, Figure 7-5) to thedrive motor.

4. Secure the cables to the AC drive with clamp (3).

5. Position anchor block (14) and secure with twoscrews (13).

6. Install AC drive motor (9, Figure 7-2) and secruewith three screws (8) and three washers (3).

7. Reconnect harness (36, Figure 7-5) to AC drivemotor (9, Figure 7-2).

8. Attach a hoist to control head (10, Figure 7-3) andlift into position,

R6586

902998 7-3

9. Slowly lower the arm assembly while rotating thepivot cap (13) to align bearings (3, Figure 7-1)with groves (4).

10. Once pivot cap sits flat on the drive motor flange,rotate and lower until bearings (3) are trappedunder the mounting flange.

11. Install bracket (1) with finger plates and stopattached. Secure with two screw (2).

12. Align bracket (1) and bracket (16, Figure 7-2) andinstall torque sensor (14) with two screws (4).

13. Reconnect control arm cable (17, Figure 7-5) tolower control cable (9).

14. Install motor cover (2, Figure 7-3).

15. Install pivot cap cover (12).

16. Lower the rear of the truck to the floor.



R6556

7-4 902998

Figure 7-5 Electrical System Components

R6572

902998 7-5

Figure 7-6 Load Wheels

7-1. LOAD WHEELS.

1. Unload the truck and block the drive wheel.

2. Raise the lift carriage approximately three feet.


4. Raise the front of the lift truck with a jack oranother lift truck and place supporting boards orsteel bars under the body, so that when the frontend is lowered it will remain about 6 inches off thefloor and the load wheel will not touch the floor.

5. Lower the lift truck onto the support.

6. Remove dust cap (10, Figure 7-6).

7. Remove nut (9) and washer (8).

8. Slide load wheel hub (4) off of spindle.

9. Remove grease seal (1) and bearings (2 and 7)

10. Clean and check bearings and grease seal fordefects.

11. Apply a lithium base general purpose grease tobearing and insert into wheel hub.

12. Insert grease seal (1) into wheel hub and packinside of wheel hub with grease.

13. Install wheel on spindle, then reinstall washer (8)and nut (9).

NOTE: Tighten the nut (9) until the load wheel cannotbe turned by hand. Then gradually loosen thenut until the load wheel can be turned withone hand freely, but not loose enough to per-mit noticeable bearing end play.

14. Wipe away excess grease from exposed areasand reinstall dust cap (10).

R106

7-6 902998

SECTION 8ELEVATION SYSTEM SERVICING

8-1. GENERAL

The elevation system includes the mast, lift chains, liftcylinder, ram head and tilt cylinders.

8-2. RAM HEAD REPLACEMENT

8-2.1. Non-Telescopic

WARNING: Before attempting any service make cer-tain power is disconnected.

1. Lower the lift carriage fully, and tilt mast all theway forward.


3. Slacken the lift chains by loosening the nut (22,Figure 8-1) below the chain adjusting bolt (17).

4. Lift the lift chains off the ram head sheaves andlay aside.

5. Remove screw (4), lock washer (2) and ram head(15).

6. Repair the ram head as required.

7. Reinstall ram head in reverse order of removal.

8. Adjust lift chains as described in paragraph 8-6.

Figure 8-1 Elevation System (Non-Telescopic)

R6560

902998 8-1

8-2.2. Telescopic

WARNING: Before attempting any service make cer-tain power is disconnected.



3. Slacken the lift chains by loosening the nut (32,Figure 8-2) below the chain adjusting bolt (17).

4. Lift the lift chains off the ram head sheaves andlay aside.

5. Remove clamp bar (13) and wear spacers (18) tofree ram head from inner mast.

6. Remove screw (24), lock washer (2) and ramhead (25).

7. Repair the ram head as required.

8. Reinstall ram head in reverse order of removal.

9. Adjust lift chains as described in paragraph 8-6.

8-3. LIFT CHAIN ADJUSTMENT


WARNING: Before attempting any adjustment makecertain power is disconnected.

1. Fully lower lift carriage.


3. Loosen nut (18, Figure 8-1) on chain adjustingbolt (17) on the lift carriage.

4. Take up slack by tightening nut (22).

CAUTION: At least 3 full threads must be presentbelow hex nut after completion of adjust-ment.

5. Secure adjustment by tightening nut (18).


7. Test chain by operating carriage. If slack is stillapparent repeat above procedure.

8-3.2. Telescopic

WARNING: Before attempting any adjustment makecertain power is disconnected.

1. Fully lower lift carriage.


3. Loosen nut (29, Figure 8-2) on chain adjustingbolt (28) on the lift carriage.

4. Take up slack by tightening nut (32).

CAUTION: At least 3 full threads must be presentbelow hex nut after completion of adjust-ment.

5. Secure adjustment by tightening nut (29).


7. Test chain by operating carriage. If slack is stillapparent repeat above procedure.

8-4. LIFT CHAIN INSPECTION

Both chains should be replaced when either chain isworn enough to increase it’s length by 3% or more. Tomake this determination proceed as follows.

Using a section of chain that sees the most frequentoperation of the chain sheaves, isolate a vertical por-tion under tension from the weight of carriage andforks.

Measure the distance between pin centers on 20 verti-cal links. If the section measures 12.88” or more, thechain should be replaced.

New chain anchor pins should be installed whenchains are replaced. Never replace a partial section ofchain and never repair a damaged chain. Refer toparagraph 8-5. when installing new chain.

8-5. LIFT CHAIN REPLACEMENT


1. Place a solid block on floor under the verticalmembers nearest the center of the lift carriage.

2. Lower lift carriage until it is supported by the blockand the load chains are slack, then disconnectbattery.

WARNING: Before attempting any actual replace-ment, make certain power is discon-nected.

3. Remove retaining ring and pin (7, Figure 8-1) fromend of chain connected to mast cross brace.

4. Remove retaining ring and pin (7) from chainadjusting bolt (17).

5. Remove chain from sheave (12) and lay aside forrepair.

6. Position new chain in place on sheave (12).

7. Connect end of chain to adjusting bolt (7) withretaining ring and pin (7).

8. Connect end of chain to mast cross brace withretaining ring and pin (7).

9. Adjust chain according to paragraph 8-3.

8-2 902998

Figure 8-2 Elevation System (Telescopic)

R6561

902998 8-3

8-5.2. Telescopic




3. Remove retaining ring and pin (7, Figure 8-1 orFigure 8-2) from end of chain connected to mastcross brace.

4. Remove retaining ring and pin (7) from chainadjusting bolt (28).

5. Remove chain from sheave (22) and lay aside forrepair.

6. Position new chain in place on sheave (22).

7. Connect end of chain to adjusting bolt (27) withretaining ring and pin (7).

8. Connect end of chain to mast cross brace withretaining ring and pin (7).


8-6. LIFT CYLINDER REMOVAL.

1. Tilt the mast all the way forward and fully lowerthe lift carriage.

WARNING: Before disconnecting any hydraulic lines,make certain the system is not underpressure. Refer to paragraph 9-1.


3. Disconnect the overflow hose (15, Figure 8-3)from top of lift cylinder.

4. Remove the hose ties (14) from the lift cylinder.

5. Remove the flow control valve as described inparagraph 9-5.

6. Remove the reducer (19) and elbow (21) from thebottom of the lift cylinder.

7. Remove the ram head as described in paragraph8-2.

8. Non-Telescopic: Remove lift cylinder clamp.

CAUTION: Hold lift cylinder securely during the finalstages of this procedure.

9. Remove screw (1, Figure 8-1 or Figure 8-2) andwashers (2 and 3) from bottom of lift cylinder.

10. Raise the lift cylinder up and out of the truck.

NOTE: Disassembly of lift cylinder is covered in SEC-TION 9.

11. Reinstall lift cylinder in reverse order of removal.


8-7. TILT CYLINDER REPLACEMENT.

WARNING: Mast must be supported by a hoistbefore removing tilt cylinders.

1. Secure mast with a hoist

2. Raise the forks to approximately three feet. Tiltthe mast all the forward.

3. Drive out roll pin (22, Figure 8-3) that secures pin(23) to mast.

4. Insert a 5/16-18 x 1 bolt into threaded hole in pin(23). Extract pin by pulling on bolt.

5. Pull tilt control to BACK position to free tilt cylinderfrom mast.

6. Reach inside access hole to remove snap rings(4) and extract pin (5).


7. Tag and disconnect the hoses from the tilt cylin-der.

NOTE: Disassembly procedures are covered in SEC-TION 9.

8. Install the new or repaired cylinder in reverseorder of disassembly.

8-4 902998

Figure 8-3 Standard Hydraulic System

R6562

902998 8-5

8-8. MAST REMOVAL.

1. Remove the lift carriage as described in para-graph 8-9.

WARNING: Block the drive wheel securely so it can-not move.

2. Raise front end of lift truck with jacks or anotherlift truck and place support blocks under truckbody to hold it approximately 6 inches off floor.

3. Lower lift truck onto the block support and removeboth load wheels as describe in SECTION 7.

4. Secure mast with a hoist or similar device.

5. Tilt the mast all the forward.

6. Drive out roll pin (22, Figure 8-3) that secures pin(23) to mast.

7. Insert a 5/16-18 x 1 bolt into threaded hole in pin(23). Extract pin by pulling on bolt.

8. Pull tilt control to BACK position to free tilt cylinderfrom mast.


9. Disconnect the hydraulic hose (17) form the liftcylinder.

10. Remove external retainer rings (31, Figure 12-4),mast support shaft (28 and 29).

11. Lift the masts from chassis frame together as aunit.

12. Installation of new or modified mast is performedin the reverse order of removal.

13. Lubricate the newly installed mast as described inSECTION 3.

8-9. LIFT CARRIAGE REPLACEMENT.




3. Remove cotter pin and clevis pin securing chainto lift carriage.

4. Telescopic: Remove stop blocks on top of mast.

5. Secure a hoist or similar device to the lift carriage.

6. Remove lift carriage from mast.

7. Installation of new or modified lift carriage is per-formed in the reverse order of removal.


8-6 902998

SECTION 9HYDRAULIC SYSTEM SERVICING

9-1. RELIEVING SYSTEM PRESSURE.

WARNING: Hydraulic system pressure must berelieved before removing hydraulic sys-tem components. Use the following pro-cedure to relieve system pressure:

1. Fully lower the lift carriage unless the procedurefor a component directs differently.


CAUTION: Use rags and a suitable container tocatch any dripping oil when the hydrauliclines are disconnected. Wipe off anyspilled oil immediately.

3. Obtain a suitable container to catch any oil thatmay escape when opening a line.

4. Open the low pressure line at any convenientconnection near the component that is to berepaired or replaced.

Figure 9-1 Pump and Reservoir Hydraulic System

R6592

ONE PIECE PUMP AND RESERVOIR

902998 9-1

9-1. FILTER REPLACEMENT (Two Piece Pump and Reservoir).




3. Remove reservoir drain plug and drain hydraulicoil into a suitable container.

4. Loosen clamps (11, Figure 9-3) and remove hose(10).

5. Remove nipple (9) and elbow (8) from filter (7).

6. Unscrew filter (7) from reservoir (31).

7. Install new filter (7).

8. Install elbow (8) and nipple (9).

9. Reinstall hose (10) and secure with clamps (11).

10. Clean the reservoir drain plug thoroughly.

11. Reinstall the drain plug.

NOTE: Refill only with Big Joe hydraulic oil, and onlywhile the lift carriage is completely lowered.Refill until oil is to the “FULL” mark on the dipstick. Refer to SECTION 3 for oil capacities.

12. Remove the dipstick (22) and fill the reservoir.


14. Operate the hydraulic controls and check forleaks.

9-2. HYDRAULIC PUMP AND MOTOR ASSEMBLY(Two Piece Pump and Reservoir)



2. Disconnect hose (16, Figure 9-3) from the pump.

3. Loosen clamps (11) and remove hose (10).

4. Tag and disconnect electrical wires from motor.

5. Remove the four hex nuts (18), lock washers (19),screws (14), and pump and motor assembly (17).

6. Remove elbow (15), nipple (12) and elbow (13)from the pump.

7. Remove the four screws (4, Figure 9-2) and lockwashers (3) to disassemble the pump from themotor.

Figure 9-2 Hydraulic Pump and Motor Assembly

8. If the pump is defective, install a new pump. Ifmotor is defective, a new motor may be installed,or motor may be rebuilt (see SECTION 10).

9. Reassemble pump (2) and motor (1) and securewith four screws (4, Figure 9-2) and lock washers(3).

10. Reinstall assembly in truck and connect hydrauliclines to pump and electrical wires to motor.

11. Clean the drain plug thoroughly.



13. Remove the dipstick (22, Figure 9-3) and fill thereservoir.



R6581

PART OF TWO PIECE PUMP AND RESERVOIR

9-2 902998

9-3. LINE, FITTING and HOSE REPLACEMENT.

NOTE: Leaking hydraulic fittings can sometimes beremedied by simply tightening the fitting. Ifthis does not remedy the leak, the fitting orline must be replaced. A leak in the suctionline between the pump and the reservoir willsometimes cause hydraulic oil to foamthrough the vent.



2. Remove the leaking line or fitting and replace itwith a new one. Refer to Figure 9-1 to Figure 9-11.




5. Remove the reservoir vent cap and fill the reser-voir.




TWO PIECE PUMPAND RESERVOIR

R6590

902998 9-3

9-4. CONTROL VALVE SERVICE

9-4.1. Control Valve Replacement


1. To access the reservoir, remove cover (10, Figure9-4)


3. To access the control valve remove cover (2, Fig-ure 9-4).

4. Remove the control knobs from the control levers.

5. Remove screws (19 and 23, Figure 9-7) andcover (18).

6. Label, disconnect and plug the hydraulic linesfrom the control valve. Label and disconnect theelectrical wires from the switches at the bottom ofthe control valve.

7. Remove the nuts (2) and washers (1). Removethe control valve.

Figure 9-4 Access Covers

R6593

9-4 902998

8. Install a rebuilt or new valve and secure nuts (2)and washers (1).

9. Connect the wires and hoses to the control valve.

10. Install cover (18) and secure with screws (19 and23).

11. Install control knobs on the control levers.




14. Remove the dip stick and fill the reservoir.

9-1.1. Brand Control Valve Repair

1. Remove cotter pins (10, Figure 9-5 or Figure 9-6)and clevis pins (9) securing control levers to thevalve spools.

Figure 9-5 Brand 2 Spool Control ValveWith Levers

2. Remove cotter pin (8) and clevis pins (7) securingcontrol levers to pivot (11).

3. Remove screws (2), washers (1) and pivot (11)from valve (12).

4. Refer to Figure 12-22 for repair of the spool valve.

Refer to Figure 12-23 for repair of the controlvalve switch.

Refer to Figure 12-24 for repair parts of the con-trol valve seal kit.

5. Reassembly in reverse order.

Figure 9-6 Brand 3 Spool Control Valve With Levers

R6568

R6566

902998 9-5

Figure 9-7 Hydraulic System (2 Spool Brand Valve)

R6563

9-6 902998


R6591

902998 9-7

Figure 9-9 Hydraulic System (2 Spool Bucher Valve)

R6564

9-8 902998

9-5. FLOW CONTROL VALVE REPLACEMENT

9-5.1. Lift Flow Control Valve

1. Raise the forks high enough to gain access to theflow control valve (20, Figure 9-10) and tilt themast all the way forward.

2. Place a strong support under the inner mast ontelescopic models or under lift carriage on non-telescopic models and lower forks so that innermast or lift carriage rests on the support.


3. Disconnect hose assembly (17) from adapter(18).

4. Remove flow control valve (20) from elbow (21).

5. Remove adapter (18) and reducers (19) from flowcontrol valve (20) and install them in the new flowcontrol valve.

6. Install new flow control valve making certain direc-tion of free flow (as marked on valve) is toward liftcylinder.

7. Reconnect hose (17).


9. Raise forks, then remove support.

10. Fully lower the lift carriage and check the hydrau-lic oil level.

11. Raise and lower the lift carriage and check forleaks.

9-5.2. Tilt Flow Control Valve

1. Raise the forks high enough to gain access to thetilt flow control valves (10, Figure 9-10) and tilt themast all the way forward.

2. Place a strong support under the inner mast ontelescopic models or under lift carriage on non-telescopic models and lower forks so that innermast or lift carriage rests on the support.


3. Disconnect hose (12) from adapter (11). Removeadapter (11) from control valve (10).

4. Remove flow control valve (10).

5. If valve is in good condition, clean and reinstallthe valve; if valve is damaged install replacementvalve.

6. Install adapter (11) and reconnect hose (12).


8. Raise forks, then remove support.

9. Fully lower the lift carriage and check the hydrau-lic oil level.

10. Raise and lower the lift carriage and check forleaks.

902998 9-9


R6562

9-10 902998

Figure 9-11 Auxiliary Hydraulic System

R6569

902998 9-11

9-6. LIFT CYLINDER REPAIR

NOTE: Removal procedures are covered in SEC-TION 8.

CAUTION: Use proper pipe clamp-type vise. Thecylinder will be distorted if the vise istightened too much.

1. Secure lift cylinder tube assembly in vise andremove gland nut (3, Figure 9-12), then wiper ring(2), and top O-ring (4).

2. Pull out cylinder ram rod (5).

3. Remove lift cylinder tube assembly from vise.

CAUTION: Use proper pipe clamp-type vise withnon-marring jaws to prevent damagingthe finish on the ram.

4. Secure cylinder ram rod (5) in vise.

5. Remove nut (10) and pull off piston (8), and O-ring (7). Remove PSP seal (9) from piston (8).

NOTE: Install Packing Kit 900119

6. Install new PSP seal (9) on piston (8).

7. Install new O-ring (7), piston (8) and nut (10) oncylinder ram (5).

8. Remove cylinder ram (5) from vise.

CAUTION: To prevent cylinder damage, use properpipe clamp vise. The cylinder will be dis-torted if the vise is tightened too much.

9. Secure lift cylinder tube (1) in vise.

10. Install cylinder ram (5) into cylinder tube (1).

11. Install new O-ring (4), and gland nut (3) with newwiper ring (2).

12. Remove lift cylinder assembly from vise.

Figure 9-12 Lift Cylinder

PACKING KIT907119

CONTAINS:

ITEM QTY2 14 17 19 1

10 1

R6571

9-12 902998

9-7. TILT CYLINDER REPAIR


WARNING: To prevent cylinder damage, use properpipe clamp vise. The cylinder will be dis-torted if the vise is tightened too much.

1. Secure the cylinder assembly in a vise andremove rod end (14, Figure 9-13). Unthread glandnut (12) from barrel (2) using spanner wrench andremove barrel (2).

2. Pull out piston rod (8).

3. Unthread nut (3).

4. Remove piston (5), o-ring (7), and gland nut (12)from piston rod (8).

5. Remove grease fittings (1) from barrel (6) and rodend (14).

NOTE: Before reassembling the hydraulic cylinder, itis recommended that Packing kit items (4, 6,7, 9, 11, and 13) be replaced.

6. Reassemble the cylinder in reverse order of dis-assembly.

Figure 9-13 Tilt Cylinder

R6504

PACKING KIT907205

CONTAINS:

ITEM QTY4 16 17 19 1

11 113 1

902998 9-13

NOTES

9-14 902998

SECTION 10ELECTRICAL COMPONENTS

10-1.ELECTRICAL CONTROL PANEL

1. To access the electrical panel, power steeringunit, drive motor, torque sensor load cell, anddrive motor remove cover (2, Figure 10-1).

2. Tag and disconnect all leads from electrical panel(37, Figure 10-2).

3. Remove four screws (39) and four washers (38)to remove panel (37).

4. Refer to Figure 12-28 to identify parts associatedwith the complete electrical control panel assem-bly.

5. Install in reverse order of removal.

Figure 10-1 Access Covers

R6593

902998 10-1


R6572

10-2 902998

10-2.HIGH SPEED LIMIT SWITCH

10-2.1.Operational Check

Perform this operation check to be sure that the highspeed limit switch is operating properly.

1. Position the lift carriage approximately 36 inchesabove the floor.

2. Drive at a moderate speed, then push the controllever to highest speed. The rate of travel shouldnot increase to top speed.

3. Stop and lower the lift carriage to approximately24 inches above the floor.

4. Drive at a moderate speed, then push the controllever to highest speed. The rate of travel shouldincrease to top speed.

10-2.2.High Speed Limit Switch Adjustment

The high speed limit switch is properly adjusted andinspected before it leaves the factory, so it rarelyneeds adjustment. If operational check indicated thatadjustment is required, proceed as follows:

1. Lower the lift carriage as far as it will go.

2. Check that switch roller is contacting the barwelded on the mast and has closed the switchcontacts (switch should not click when roller armis manually moved father toward the switch body).When roller arm is manually moved toward switchbody, there should be at least 1/16 inch clearancebetween roller and bar on mast.

NOTE: Roller arm is spring loaded and will requireexertion of some pressure to check this clear-ance.

3. If roller does not contact bar on mast or if switchclicks when roller is manually moved toward theswitch body, loosen locknut on the roller arm,adjust roller arm away from switch body, andtighten locknut.

4. If roller cannot be manually moved to clear the baron the mast, loosen locknut on the roller arm,

adjust roller arm toward switch body, and tightenlocknut.

5. Repeat step 2. to check adjustment.

6. Raise the lift carriage so that the switch roller trav-els above the end of the bar on the mast.

7. Check that switch roller is not touching the mastface and has opened switch contacts (listen foraudible click when roller arm is manually movedtoward switch body and another click whenreleased).

8. If roller arm touches mast face, loosen locknut onthe roller arm, adjust arm toward switch body, andtighten locknut.

9. If switch does not audibly click when roller arm ismanually moved toward switch body, replaceswitch.

10. Repeat step 2. to check adjustment.

10-3.PUMP MOTOR.


Refer to Figure 12-30 for motor disassembly.

10-4.DRIVE MOTOR.


Refer to Figure 12-29 for motor disassembly.

10-5.BATTERIES.

1. Turn key to off, and remove from key switch.

NOTE: Batteries are heavy. Use care when lifting outof battery compartment.

2. Disconnect the battery quick disconnect.

3. Lift the battery out of the battery compartment.

4. Lower the new battery in the battery compart-ment.

5. Reconnect the battery quick disconnect.

902998 10-3

NOTES

10-4 902998

SECTION 11OPTIONAL EQUIPMENT

11-1.KEYSWITCH

The optional keyswitch is shown in Figure 12-31 andFigure 4-1 for wiring information.

11-2.REMOTE CONTROL.

Refer to Figure 12-32 removal and parts identificationof the remote control option and Figure 4-1 for wiringinformation.

11-3.HOUR METER/BATTERY CAPACITY INDICA-TOR

Refer to Figure 12-33 for replacement parts.

11-4.LIFT LIMIT SWITCH OVERRIDE

Refer to Figure 12-34 for replacement parts.

902998 11-1

NOTES

11-2 902998

SECTION 12ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the PDCE Lift Truck.

902998 12-1

Figure 12-1 Steering Arm

R6556

12-2 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 506585 CONTROL ARM ASSEMBLY 1

1 052780 . SCREW-SHOULDER,1/4 X 1, NYLOK

4

2 074280-01 . SHIM-SPRING 8

3 051242 . BEARING-BALL, 1/4 ID X 3/4 OD, SLD

4

4 506564 . PIVOT CAP 1

5 065525 . SCREW-SBHC, 1/4-20 X 5/8 NYLOK

6

6 059526 . NUT-HEX, JAM 5/16-18 UNC 2

7 077210 . WASHER-LOCK, SPLIT, 5/16 2

8 285302 . PIN-SPRING 1

9 285303 . PIN-SPRING 1

10 053042 . BUMPER-ROUND 2

11 071377 . SCREW-PH TR HD,10-32 X 3/4

4

12 404988 . PLATE-SENSOR FINGER 2

13 065605 . SCREW-HSHC, 3/8-16 X 1 4

14 061000 . PIN-ROLL, SPLIT, 1/4 DIA X 5/8 5

15 404985 . BRACKET-MTG, ACTUATOR 1

16 404984 . STOP BLOCK-ARM 1

17 065481 . SCREW-HX SOC HD, 1/4-20 X 1 6

18 053044 . BUMPER-RING, GBR-3 2

19 077030 . WASHER-FLAT, #10 2

20 060582 . PIN-DOWEL, 0.188 X 0.75 4

21 404196 . CAM-DEAD MAN 1

22 800310 . ARM-CONTROL 1

23 — . CONTROL HEAD (FIGURE 12-2) REF

24 404197 . CAM-CREEP 1

25 065569 . SCREW-SOC HD, 7/16-14 X 2-1/4

2

26 401127 . SPACER 1

27 075060 . HANDLE-RETURN SPRING 1

28 501371 . TUBE ASSY-HANDLE RETURN SPRING

1

29 052925 . BUSHING,-FLANGE, BRONZE 1

30 800204 . CLAMP-SPRING TUBE 1

31 052922 . BUSHING,-FLANGE, BRONZE 1

32 404210 . BAR-LIMIT SWITCH MOUNT 2

33 020775 . SWITCH-MINIATURE, SNAP ACTION

2

34 065472 . SCREW-SHCS, 4-40 UNC X 3/4 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-3

Figure 12-2 Control Head Assembly

R6555

SEE FIGURE 12-3FOR COLD CONDITIONING

12-4 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 506124-05 CONTROL HEAD-STANDARD, RUBBER HAND GRIPS

1

— 506124-06 CONTROL HEAD-STANDARD, COLD CONDITIONING, RUBBER HAND GRIPS

1

— 506124-07 CONTROL HEAD- REMOTE LIFT & LOWER, RUBBER HAND GRIPS

1

— 506124-08 CONTROL HEAD-REMOTE LIFT & LOWER, COLD CONDITIONING, RUBBER HAND GRIPS

1

— 506626-01 CONTROL HEAD-STANDARD, ALUMINUM HAND GRIPS

1

— 506626-02 CONTROL HEAD-STANDARD, COLD CONDITIONING, ALUMINUM HAND GRIPS

1

— 506626-03 CONTROL HEAD- REMOTE LIFT & LOWER, ALUMINUM HAND GRIPS

1

— 506626-04 CONTROL HEAD- REMOTE LIFT & LOWER, COLD CONDITIONING, ALUMINUM HAND GRIPS

1

1 800274 . COVER-SAFETY 1

2 061016 . PIN-ROLL, 1/4 X 3 2

3 402843 . PAD 2

4 075510 . SPRING-COMPRESSION 2

5 059633 . NUT-HEX LOCK, 2-56 2

6 018202 . INSULATOR-SWITCH 1

7 020669 . SWITCH-MICRO 1

8 070486 . SCREW-PAN HD, BRASS 2

9 052956 . BEARING-FLANGED 2

10 056617 . DECAL-FORWARD-REVERSE 1

11 069462 . SCREW-FLAT HD SLOTTED, 6-32 X 3/4

2

12 067416 . SCREW-PAN HEAD, 6-32 x 1/2 8

13 402830 . COVER-TOP 1

14 072415 . SCREW-PAN HD, THREAD CUTTING, 4-40 X 5/8

2

15 400546 . ROD ASSY-CONNECTING 2

16 058106 . CLAMP 1

17 057262 . DISK-POTENTIOMETER 1

18 061750 . RING-“E” RETAINING 2

19 074724 . SPACER 1

20 053366 . SPRING-RETURN 1

21 402836 . SPACER 2

22 075088 . SPRING-RETURN 1

23 061200-01 . PIN-SPIROL, 3/16 X 1 1

24 505323 . HARNESS ASSEMBLY-POTENTIOMETER & WIRE

1

25 017580 . . POTENTIOMETER 1

26 068180 . SCREW-ROUND HD, 4-40 X 1-1/2

2

27 505052 . BRACKET ASSY-SWITCH 1

28 402837 . BRACKET 1

29 072400-01 . SCREW-SLOTTED HEX, 6-32 X 1/2

4

30 077204 . WASHER-SPLIT LOCK, #6 4

31 077007 . WASHER 4

32 020775 . SWITCH-MICRO 2

33 059634 . NUT-HEX LOCK, 4-40 2

34 402840 . CAM 1

35 074711 . SPACER-CONNECTING ROD 1

36 069478 . SCREW-PHILLIPS FLAT HD, 1/4-20 X 3/4

4

37 402841 . GUARD-HANDLE 1

38 402828 . CAP 2

39 069715 . SCREW-SOCKET FLAT HD, 1/4-20 X 3/4

2

40 402827 . SHAFT 1

41 403358 . GRIP-ALUM 2

41 404421 . GRIP-RUBBER CLAD 2

42 060942 . PIN-ROLL, 1/8 X 1-1/4 2

43 800272 . LEVER-CONTROL 2

44 073461 . SCREW-SOCKET SET 2

45 060579 . PIN-DOWEL, 1/4 X 15/16 2

46 402839 . TUBE 1

47 023298 . WIRE HARNESS ASSEMBLY,STANDARD

1

47 023297 . WIRE HARNESS ASSEMBLY,REMOTE LIFT & LOWER

1

48 005649 . CONNECTOR (FOR COLD CONDITIONING)

1

49 069463 . SCREW-FLAT HD SLOTTED, 6-32 X 1

2

50 800273 . CONTROL HANDLE 1

51 504538-01 . WIRE ASSEMBLY 2

52 005647 . CONNECTOR 1

53 402830 . COVER-BOTTOM 1

54 020697 . SWITCH-PUSHBUTTON 2

55 056641-03 . DECAL-LIFT 1

56 056641-04 . DECAL-LOWER 1

57 402842 . PLATE-SWITCH 1

58 067415 . SCREW-PAN HD, 3-32 X 1/4 4

59 056624 . DECAL-HORN 1

60 020776 . SWITCH-HORN PUSHBUTTON 1

61 053215-02 . PLUG-HOLE 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-5

Figure 12-3 Control Head Cold Conditioning

R3966

12-6 902998

AR - AS REQUIRED

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 018909 RESISTORS 2

2 068187 SCREW 2

3 023014 WIRE AR

4 400544 BRACKET-RESISTOR 1

5 018214 INSULATOR-SWITCH 1

6 402829 BRACKET 1

7 077007 WASHER- FLAT 2

8 077204 WASHER-SPLIT LOCK, #6 2

9 072400-01 SCREW-HEX HD. SLOTTED, 6-32 X 1/2

2

10 059632 NUT, HEX, 5-40 2

11 400044 BRACKET-THERMAL CUTOUT 1

12 020736 THERMAL CUTOUT 1

13 005643 SWITCH-CONTACT PIN 2

14 403372 BUSHING-INSULATION 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-7


R6558

12-8 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 057710 HANDLE-PULL, RECESS 3

2 506569 COVER-MOTOR, PDCE 1

3 071384 SCREW-PH TRS HD, #10-32 X 1 2

4 053042 BUMPER-ROUND 2

5 405023 SPACER-ROUND, BUMPER 2

6 065542 SCREW-BTN HD, 3/8-16 X 3/4 16

7 404991 COVER-FILLER PLATE 1

8 059940-03 NUT-CAGE, 3/8-16, 1/4 PANNEL 14

9 — AC DRIVE & STEERING SYSTEM ASSY (FIGURE 12-5)

REF

10 — CONTROL HEAD (FIGURE 12-2) REF

11 065532 SCREW-BTN HD, 1/4-20 X 3/8 2

12 404983 COVER PLATE-PIVOT CAP 1

13 — ARM ASSY-CONTROL (FIGURE 12-1)

REF

14 065616 SCREW-HX SOC HD, 1/2-13 X 1.75

12

15 404738 COVER-WEIGHT BOX 1

16 404737 COVER-TOP, CHASSIS 1

17 — ELEVATION SYSTEM (FIGURE 12-8 OR FIGURE 12-9)

REF

18 — LIFT CARRIAGE (FIGURE 12-10) REF

19 073507 SEAL-GREASE 2

20 051141 CONE-BEARING 2

21 051142 CUP-BEARING 2

22 503389 LOAD WHEEL-SMOOTH POLY 2

— 800202 . HUB 1

— 079163 . POLYURETHANE WHEEL 1

23 053400 CAP-DUST 2

24 059128 NUT- LOCK, HEX, 3/4-16 2

25 077082 WASHER 2

26 051143 CONE-BEARING 2

27 051144 CUP-BEARING 2

28 077074 WASHER 2

29 077029 WASHER 2

30 400309 SHAFT 1

31 061729 RING-SNAP, 10025 2

32 404365 PIN-COVER LOCATING 2

33 — CHASSIS 1

34 057520 GROMMET-SNAP, 1/2 ID, 1.12 OD 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-9

Figure 12-5 AC Drive and Steering System

R6557

12-10 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 506592 AC DRIVE & STEERING SYSTEM ASSY

1

1 064617 SCREW-HEX HD, 3/8-16 X 3 1

2 064620 SCREW-HES, 3/8-16 X 3-3/4 2

3 077211 WASHER-LOCK, SPLIT, 3/8 6

4 065610 SCREW-SOC HD, 3/8-16 X 2.25 2

5 069706 SCREW-SOC FL HD, 1/2-13 X 1 2

6 061029 PIN-ROLL 3

7 405000 SPACER-STEERING MOTOR 1

8 064612 SCREW-HEX HD, 3/8-16 X 2 3

9 005684 POWER STEERING UNIT, TORQUE MODEL

1

10 063559 SCREW-HX HD CAP, 5/16-18 X 1.5

6


12 016058 MOTOR-DRIVE, AC, ABM (FIGURE 12-29)

REF

13 405001 ISOLATER-TORQ SENSOR 4

14 013835 LOAD CELL-TORQUE SENSOR 1

15 059480-01 NUT-HEX, NYLOCK, METRIC, M20

1

16 404986 BRACKET-MTG, SENSOR 1

17 404624 ADAPTER PLATE-STEERING 1

18 067446-01 SCREW-HEX SOC HD, M2 6

19 800326 MTG PLATE-MACHINED, PVTG 1

20 — TRANSMISSION ASSY-GK20, AC(FIGURE 12-6)

REF

21 — . GEAR-STEERING(FIGURE 12-6)

REF

22 079136-02 . WHEEL-DRIVE, SMOOTHCROWN POLY (STD)

1

22 079136-01 . WHEEL-DRIVE, SMOOTHFLAT POLY

1

23 059901 KIT-WHEEL NUT AND WASHER, M14

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-11

Figure 12-6 Transmission

R6570

12-12 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 506561 TRANSMISSION ASSY-GK20, AC 1

1 — . GEAR-STEERING 1

2 907197 . PLUG-FILL 1

3 907195 . PLUG-DRAIN 1

4 907196 . SEAL-PLUG 2

5 907198 . SEAL-DRIVE AXLE 1

6 — WHEEL-DRIVE (FIGURE 12-5) REF

7 — KIT-WHEELNUT AND WASHER, M14 (FIGURE 12-5)

REF

8 — POWER STEERING UNIT, TORQUE MODEL (FIGURE 12-5)

REF

9 — NUT-HEX, NYLOCK, METRIC,M20 (FIGURE 12-5)

REF

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-13

Figure 12-7 Decal Location

R6559

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 056564* DECAL-CAUTION 2

2 056631* DECAL-BIG JOE 1

3 056592* DECAL-WARNING 1

4 056606 DECAL-BIG JOE 1

5 056499* DECAL- NO RIDING 1

6 056625* DECAL-WARNING 1

7 066050* SCREW-DRIVE, RD HD, #2U X 1/4

4

8 061334* NAMEPLATE (STD) 1

8 061335* NAMEPLATE (W/ATTACHMENT) 1

9 056633* DECAL-MAST, BIG JOE, LARGE 2

10 056494* DECAL-WARNING, LWR FORKS 1

11 056696 DECAL-BIG JOE SUPPORT 2

12 056626* DECAL-OIL LEVEL 1

13 056646* DECAL-CAUTION, BATTEY 1

— 056683 DECAL-AMERICAN BUILT 2

* PART OF KIT NUMBER 900598.

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-14 902998

NOTES

902998 12-15

Figure 12-8 Elevation System (Non-Telescopic)

R6560

12-16 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 064605 SCREW-HEX HD, 3/8-16 x 1 1

2 077213 WASHER,-LOCK, SPLIT, 1/2 2

3 077076 WASHER,-13/32 X 1-1/2 X 7 GA 1

4 063478 SCREW-HEX HD, 1/4-20 X 3/4 2


6 402322 BRACKET-SWITCH 1

7 060314 PIN-CHAIN, W/ RETAINING RINGS

4

8 — OUTER MAST 1

9 025713 FITTING-GREASE, 3/16 DRV, BL CHK

2

10 061729 RING-SNAP, EXT, 1-1/4 DIA 2

11 053013 WASHER-THRUST 4

12 289202 SHEAVE-HEAVY DUTY 2

13 051210 BEARING-ROLLER, SHEAVE 2

14 064711 SCREW-HX HD, 1/2-13 X 1-3/4 1

15 313101 RAM HEAD 1

16 313200 LIFT CHAIN (CHAIN LENGTH 7.45 FT)

2

17 312203 CHAIN LUG-ADJ 2

18 059547 NUT-HEX, JAM, 3/4-16 UNF 2


20 077077 WASHER-ROUND, 0.09 THK A/R

20 077078 WASHER- ROUND, 0.12 THK A/R



21 062320 ROLLER-MAST, BALL BEARING 4

22 059447 NUT-HEX, 3/4-16 UNC 2


24 059429 HEX-NUT, 3/8-16 2


26 402043-01 CLAMP-CYLINDER, 4” DIA 1

27 — LIFT CYLINDER (FIGURE 12-25) REF

28 061023 PIN-ROLL, 5/16 DIA x 3/4 1

AR - AS REQUIRED

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-17

Figure 12-9 Elevation System (Telescopic)

R6561

12-18 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 064605 SCREW- HEX HD, 3/8-16 x 1 1


3 077076 WASHER-13/32 X 1-1/2 X 7 GA 1

4 063478 SCREW-HEX HD, 1/4-20 X 3/4 2


6 402322 BRACKET-SWITCH 1

7 060314 PIN-CHAIN, W/ RETAINING RINGS

4

8 — OUTER MAST 1





10 062320 ROLLER-MAST, BALL BEARING 8

11 064609 SCREW-HX HD, 3/8-16 X 1-1/2 4


13 239520 BAR-CLAMP, LIMITED FREE LIFT 1

14 — INNER MAST 1

15 402812 SHIM 4

16 191162 BAR, DRILLED 2

17 069607 SCREW-PH FL HD, 3/8-16 X 1-1/2 4

18 100016 SPACER-WEAR 2

19 053013 WASHER-THRUST 4

20 025713 FITTING-GREASE, 3/16 DRV, BL CHK

2

21 061729 RING-SNAP, EXT, 1-1/4 DIA 2

22 289202 SHEAVE-HEAVY DUTY 2

23 051210 BEARING-ROLLER, SHEAVE 2

24 064711 SCREW-HX HD, 1/2-13 X 1-3/4 1

25 501437 RAM HEAD 1

26 — LIFT CYLINDER(FIGURE 12-25)

REF

27 313200 LIFT CHAIN LIFT HEIGHT 106 IN.,(CHAIN LENGTH 14.83 FT)

2


2


2


2

28 312203 CHAIN LUG, ADJ 2

29 059547 NUT-HEX, JAM, 3/4-16 UNF 2



32 059447 NUT-HEX, 3/4-16 UNC 2

33 061023 PIN-ROLL, 5/16 DIA x 3/4 1

AR - AS REQUIRED

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-19

Figure 12-10 Lift Carriage

R6565

12-20 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 057159 HOOK-TYPE FORK, 30 X 1-3/4 2

1 057129 HOOK-TYPE FORK, 36 X 1-1/2 2

1 057112 HOOK-TYPE FORK, 42 X 1-3/4 2

1 057113 HOOK-TYPE FORK, 48 X 1-3/4 2

2 063820 * SCREW-HEX HD CAP 2

3 077215 * WASHER-LOCK, 5/8 2

4 401527 * BAR, FORK RETAINER 2

5 504381-01 CARRIAGE-LIFT, 32 IN WIDE(NON-TEL)

1

5 504381-07 CARRIAGE-LIFT, 36 IN WIDE(NON-TEL)

1

5 504664-01 CARRIAGE-LIFT, 32 IN WIDE(TEL)

1

5 504664-07 CARRIAGE-LIFT, 36 IN WIDE(TEL)

1

6 063820 ** SCREW-HEX HD CAP 4

7 077215 ** WASHER-LOCK, 5/8 4

8 077066 ** WASHER-ROUND 2

9 504245-03 LOAD BACKREST, 32 X 48” HIGH

9 504245-06 LOAD BACKREST, 36 X 48” HIGH

* NOT USED WITH LOAD BACKREST

** USED WITH LOAD BACKREST

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-21


R6592

ONE PIECE PUMP AND RESERVOIR

12-22 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 026500 REDUCER-3/8 NPT MALE, 1/4 NPT FEML

1

2 025501 ELBOW-1/4 NPT MALE, 1/4 TUBE FEML

1

3 056110 CLAMP-HOSE 1

4 308900 HOSE-HYDR, LOW PRESSURE, 5/8” ID

AR

5 026128 NIPPLE-HOSE, 3/8 1

6 026707 ELBOW-STREET, 3/8 NPT MALE/FEML

1

7 — TUBING-VINYL, 1/4” OD (FIGURE 12-13)

REF

8 025535 ELBOW-#6 SAE MALE, 3/8 SWVL FEML

1

9 504312-06 HOSE ASSY-FEMALE SWIVEL, 3/8

1

10 503518 DIPSTICK ASSY 1

11 016622 PUMP, MOTOR & RSVR ASSY 1

12 063553 SCREW-HX HD, 5/16-18 X 3/4 LG 4


INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-23


R6590

TWO PIECE PUMP AND RESERVOIR

12-24 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 405142 PIPE-SPACER, 3/8, RSVR 1

2 077011 WASHER-3/8 X X7/8 X 14 GA AR

3 308900 HOSE-HYDR, LOW PRESSURE, 5/8” ID

AR


5 026128 NIPPLE-HOSE, 3/8 1


1

7 035114 FILTER-TANK, 5GPM, 100 MESH 1

8 026709 ELBOW 1

9 800145 NIPPLE-MACHINED 1

10 318200 HOSE-SUCTION, 3/4” NEOPRENE AR

11 056105 CLAMP-CABLE 2

12 800328 NIPPLE-MACHINED 1

13 025141 ADAPTR-ELBW, 10 SAE M,8 NPSM SWVL

1

14 064607 SCREW-HEX HD, 3/8-16 X 1-1/4 4


1


1

17 016913 PUMP & MTR ASSY 1

18 059429 NUT-HEX, 3/8-16 4


20 064619 SCREW-HEX HD, 3/8-16 X 3-1/2 1

21 — TUBING-VINYL, 1/4” OD (FIGURE 12-13)

REF

22 506666 BREATHER CAP & DIPSTICK ASSY

1

23 025320 COUPLING-W/HEX, FEM, 3/8 NPT 1


1

25 026152 NIPPLE-PIPE, 3/8, SCH 80 1

26 026506 REDUCER-PIPE, 3/4 - 3/8 1

27 063482 SCREW-HEX HD, 1/4-20 X 1-1/4 1


29 077030 WASHER-1/44 X 9/16 X 16 GA 1

30 405143 PIPE-SPACER, 1/4, RSVR 1

31 505831 RESERVOIR 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-25


R6562

12-26 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 063553 SCREW-HX HD, 5/16-18 X 3/4 10


3 405027 HOSE PAN-NARROW 1

4 061725 RING-SNAP, EXTERNAL, 1” SHAFT

4

5 404736 PIN-TILT, REAR MAST 2

6 — CYLINDER ASSY-TILT, HYDR (FIGURE 12-26)

2


2


2

9 027112 TEE-MALE BRANCH, 1/4 NPT, 1/4 SWVL

2

10 048134-01 VALVE-RESTRICTOR, 0.031 DIA, 1/4 NPT

1

11 026920 ADAPTER-#6 SAE MALE, 1/4 SWVL FEML

2


2

13 025526 ELBOW-45° MALE, 1/4 NPT, 1/4 SWVL

4

14 056137-01 TIE-CABLE, LARGE AR

15 282500 TUBING-VINYL, 1/4” OD AR


1


1

18 026912 ADAPTER-3/8 NPT MALE, 3/8 SWVL MALE

1

19 026504 REDUCER-1/2 NPT MALE, 3/8 NPT FEML

2

20 047107 VALVE-FLOW CONTROL, 7 GPM 1

21 025538 ELBOW-MALE, 3/8 NPT 1

22 060976 PIN-ROLL, SPLIT, 3/16 DIA X 1.5 2

23 296602 PIN-MTG, FRONT, TILT CYL 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-27


R6563

12-28 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.


2 059426 NUT-HEX, 5/16-18 UNC 3

3 023312 HARNESS ASSY-VALVE, 2 SPOOL

1

4 — VALVE ASSY-2 SPOOL, BRAND (FIGURE 12-19)

REF

5 025111 ADAPTER-#10 SAE MALE, 3/8 NPT FEML

2

6 025525 ELBOW-MALE, 3/8 NPT, 3/8 SWL 1

7 — HOSE ASSY-FEMALE SWIVEL, 3/8 (FIGURE 12-11 OR FIGURE 12-12)

REF

8 — HOSE ASSY-FEMALE SWIVAL, 3/8 (FIGURE 12-13)

REF


REF

10 025120 ELBOW-1/4 SWVL MALE, 1/4 SWVL FEML

2


1


2

13 038502 GUARD-SUCTION HOSE, SPRING (30”)

AR

14 — HOSE-HYDR, LOW PRESS, 5/8” ID (FIGURE 12-11 OR FIG-URE 12-12)

REF


16 026128 NIPPLE-HOSE, 3/8 1


1

18 506598-01 COVER PLATE WLDMT-2 SPOOL 1

19 069483 SCREW-PH FL HD, 1/4-20 X 1.5 1

20 056637-02 INSERT DECAL-TILT 1

21 056637-01 INSERT DECAL-LIFT/LWR 1

22 063555 SCREW-HX HD, 5/16-18 X 1 3

23 069478 SCREW-PH FL HD, 1/4-20 X 3/4 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-29


R6591

12-30 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.


2 059426 NUT-HEX, 5/16-18 UNC 3

3 023317 HARNESS ASSY-VALVE, 3 SPOOL

1

4 — VALVE ASSY-3 SPOOL, BRAND (FIGURE 12-19)

REF


2

6 025525 ELBOW-MALE, 3/8 NPT, 3/8 SWL 1

7 — HOSE ASSY-FEMALE SWIVAL, 3/8 (FIGURE 12-11 OR FIGURE 12-12)

REF


REF


REF


2


1


2


AR


REF


16 026128 NIPPLE-HOSE, 3/8 1


1

18 506598-02 COVER PLATE WLDMT-3 SPOOL 1

19 069483 SCREW-PH FL HD, 1/4-20 X 1.5 1



22 063555 SCREW-HX HD, 5/16-18 X 1 3

23 069478 SCREW-PH FL HD, 1/4-20 X 3/4 1

24 056637-ZZ INSERT DECAL-ATTACHMENT 1

25 282700 HOSE-PRESSURE, 1/4 ID AR

26 026916 FITTING-HOSE, FEMALE SWIVEL, 1/4

2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-31

Figure 12-16 Hydraulic System (2 Spool Bucher Valve)

R6564

12-32 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 023311 HARNESS ASSY-VALVE, RMT 1

2 059429 NUT-HEX, 3/8-16 UNC 2


4 — VALVE ASSY-2 SPOOL, W/ RMT L & LWR, BUCHER (FIGURE 12-21)

REF


AR


REF


8 026128 NIPPLE-HOSE, 3/8 1


1

10 026922 ADAPTER-#6 SAE MALE, 3/8 SWVL MALE

1


2

12 505086-04 HOSE ASSY-FEMALE SWIVAL, 3/8

1


REF


REF


2

16 027103 TEE-MALE STRT RUN, #6 SAE, 3/8 SWVL

2


2

18 026316-01 PLUG-HEX, #6 SAE O-RING 4

19 026316-02 PLUG-HEX, #8 SAE O-RING 1


1

21 — HOSE ASSY-FEMALE SWIVAL, 3/8 (FIGURE 12-11 OR FIGURE 12-12)

REF

22 506498 COVER PLATE WLDMT-BUCHER VALVE

1

23 069483 SCREW-PH FL HD, 1/4-20 X 1.5 1



26 069478 SCREW-PH FL HD, 1/4-20 X 3/4 1

27 064605 SCREW-HX HD, 3/8-16 X 1 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-33

Figure 12-17 Auxiliary Hydraulic System

R6569

12-34 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 800095 SCREW-PLUG 1

2 313104 RAM HEAD (NON-TEL) 1

2 504024 RAM HEAD (TEL) 1

3 074260 SHEAVE-IDLER, RAMHEAD 2

4 401206 SP[ACER-TUBE 1

5 401552 BOLT-SHOULDER, DRILLED 1

6 025713 FITTING-GREASE, 3/16 DRIVE W/CHK

2

7 — HOSE-PRESSURE, 1/4 ID (FIGURE 12-15)

AR

8 063482 SCREW-HX HD, 1/4-20 X 1.25 2


10 401204 CLAMP-HOSE, DOUBLE 2

11 026926 COUPLING-HOSE, 1/4 NPT MALE SWVL

2

12 025333 NIPPLE-QUICK CONN, 1/4 NPT, FEML

2

13 025332 COUPLING-QUICK CONN, 1/4 NPT, FEML

2

14 026110 NIPPLE-HEX, 1/4 NPT 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-35

Figure 12-18 Hydraulic Pump and Motor Assembly

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 016913 PUMP AND MOTOR ASSEMBLY 1

1 — . PUMP MOTOR (FIGURE 12-30) REF

2 900896-09 . PUMP (COMPLETE) 1

3 077210 . LOCKWASHER, 5/16 4

4 063557 . SCREW-HEX HD CAP,5/16-18 X 3/4

4

R6581


12-36 902998


R6568

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 506584 VALVE, 2-SPOOL (STD)

1


2 065477 SCREW-HX SOC HD, 1/4-20 X 5/8 2

3 506583-02 HANDLE WLDMT-VALVE 1

5 057952 KNOB 2

6 506583-01 HANDLE WLDMT-VALVE 1

7 060326 PIN-CLEVIS, 1/4 DIA X 2-1/4 1

8 060417 PIN-COTTER, 3/32 DIA X 3/4 1

9 060316 PIN-CLEVIS, 1/4 DIA X 7/8 2

10 060417 PIN-COTTER, 3/32 DIA X 3/4 2

11 506582 PIVOT WLDMT-2 SPOOL 1

12 — VALVE-2 SPOOL, BRAND(FIGURE 12-22)

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-37


R6566

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 506604 VALVE, 3-SPOOL (STD)

1


2 065477 SCREW-HX SOC HD, 1/4-20 X 5/8 3

3 506583-03 HANDLE WLDMT-VALVE, STRAIGHT

1

4 506583-02 HANDLE WLDMT-VALVE, LH 1

5 057952 KNOB 3

6 506583-01 HANDLE WLDMT-VALVE, RH 1

7 060327 PIN-CLEVIS, 1/4 DIA X 3-1/2 1

8 060403 PIN-COTTER, 1/16 DIA X 1/2 1

9 060316 PIN-CLEVIS, 1/4 DIA X 7/8 3

10 060417 PIN-COTTER, 3/32 DIA X 3/4 3

11 506605 PIVOT WLDMT-3 SPOOL 1

12 — VALVE-3 SPOOL, BRAND(FIGURE 12-22)

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-38 902998

Figure 12-21 Bucher Control Valve

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 048183 VALVE, 2-SPOOL (NON-TEL & TEL)

1

R6567

1

902998 12-39

Figure 12-22 Brand Stack Control Valve

INDEX NO.

PART NAME 2 SPOOL 3 SPOOL

PARTNUNBER

NO.REQD.

PARTNUNBER

NO.REQD.

— CONTROL VALVE 048170 1 048172 1

1 . OUTLET SECTION 907166 1 907166 1

2 . AUX. SECTION NA 0 907171 1

3 . TILT SECTION 907154 1 907154 1

4 . LIFT SECTION 907155 1 907155 1

5 . INLET SECTION 907167 1 907167 1

— . TIE ROD KIT 907168 1 907169 1

6 . . TIE ROD 907128 3 907152 3

7 . . HEX NUTS, 5/16-24, GRADE 2 — 6 — 6

8 . . LOCK WASHER, 5/16 — 6 — 6

9 . MOUNTING BRAKET — 3 — 3

10 . SHIM WASHERS 907136 9 907136 12

11 . SWITCH ASSEMBLY (FIGURE 12-23) — 2 — 3

12 . SCREW, CAP — 8 — 12

— . SINGLE SECTION SEAL KIT 907173 * 3 907173 * 4

— . STACK VALVE SEAL KIT (FIGURE 12-24) — 2 — 3

* SEAL KIT CONSISTS OF O-RINGS THAT SEAL BETWEEN SECTIONS. THERSE O-RING ARE ALREADY INCLUDED WITH COMPLETE SECTIONS BUT MAY BE ORDERED SEPARATELY IF NEEDED.

R6538

6

6

7

7

8

8

1

9

67 8

2 3 4

11 11 11

9

8

8

8

7

79

7

105

12

12-40 902998

Figure 12-23 Stack Valve Switch Figure 12-24 Stack Valve Seal Kit

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 907129 SWITCH ASSEMBLY 3

1 907130 . SWITCH 1

2 907133 . SPRING CENTERING SPACER 1

3 907137 . SWITCH PLUNGER (LIFT/LOWER)

1

3 907134 . SWITCH PLUNGER (TILT)

1

4 907132 . SPRING GUIDE 2

5 907131 . CENTERING SPRING 1

6 907135 . SWITCH HOUSING 2

1

2

3

4

5

6

R5978

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 907127 SEAL KIT 1

1 — . O-RING 1

2 — . O-RING 1

3 — . BACK-UP RING 1

4 — . PLUG 1

.

.

.

R5979

1

1

2

3

4

902998 12-41

Figure 12-25. Lift Cylinder

PACKING KIT907119

CONTAINS:

ITEM QTY2 14 17 19 1

10 1

R6571

INDEX NO. PART NAME

LIFT HEIGHT (INCHES)

QTY60 106 130 154 168

PART NO. PART NO. PART NO. PART NO. PART NO.

— LIFT CYLINDER ASSY 504386-01 504386-02 504386-03 504386-04 504386-05 1

1 . TUBE ASSY — — — — — 1

2* . WIPER RING 049502 049502 049502 049502 049502 1

3 . GLAND NUT 800049 800049 800049 800049 800049 1

4* . TOP O-RING 042114 042114 042114 042114 042114 1

5 . RAM ROD — — — — — 1

6 . RAM STOP 272215 272216 272216 272216 272216 1

7* . BOTTOM O-RING 042105 042105 042105 042105 042105 1

8 . PISTON 403949 403949 403949 403949 403949 1

9* . PSP SEAL 042205-03 042205-03 042205-03 042205-03 042205-03 1

10* . JAM NUT, 3/4-16 800293 800293 800293 800293 800293 1

11 ROLL PIN, 5/16 X 3/4 061023 061023 061023 061023 061023 1

* 907119 PACKING KIT INCLUDES 2, 4, 7, 9 AND 10.

12-42 902998

Figure 12-26. Tilt Cylinder

R6504

PACKING KIT907205

CONTAINS:

ITEM QTY4 16 17 19 1

11 113 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 047543 TILT CYLINDER ASSY 1

1 — . GREASE ZERK 2

2 — . BARREL 1

3 — . NUT 1

4 — * . WEAR RING 1

5 — . PISTON 1

6 — * . PSP SEAL 1

7 — * . O-RING 1

8 — . PISTON ROD 1

9 — * . O-RING 1

10 — . BACKUP WASHER 1

11 — * . POLYPAK (TYPE B) 1

12 — . GLAND NUT 1

13 — * . ROD WIPER 1

14 — . ROD END 1

— — . SETSCREW 1

* PART OF KIT NUMBER 907205

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-43


R6572

12-44 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 065476 SCREW-HX HD, 1/4-20 X 1/2 3


3 056135 CLAMP-LOOP, CUSHIONED, 1.250 DIA

3

4 901451 OVER SLEEVE-CABLE, BRAIDED 1

5 059421 NUT-HEX, 1/4-20 UNC 3

6 — CABLE ASSY-DRIVE MOTOR U (FIGURE 12-28)

REF

7 — CABLE ASSY-DRIVE MOTOR V (FIGURE 12-28)

REF

8 — CABLE ASSY-DRIVE MOTOR W (FIGURE 12-28)

REF

9 — CABLE ASSY-LOWER CONTROL CABLE (FIGURE 12-28)

REF

10 — TORQUE SENSOR LEAD (PART OF TORQUE SENSOR LOAD CELL)

REF

11 056113 TIE-CABLE AR

12 005324-01 GRIP-CORD, STRAIN RELIEF 1

13 065555 SCREW-HX SOC HD, 5/16-18 X 1 2

14 404987 ANCHOR BLOCK-CORD 1

15 023310 HARNESS ASSY-DRIVE MOTOR 1

16 005640 CONNECTOR-HOUSING, SOCKET

1

17 023315 CABLE ASSY-CONTROL ARM 1

18 056139 CLAMP-LOOP, CUSHIONED, 0.75 DIA

1

19 065525 SCREW-BTN HD, 1/4-20 X 5/8 1

20 023300 HARNESS ASSY-BRAKE, DEAD-MAN, CREEP

1

21 023299 HARNESS ASSY-SWITCHES 1

22 021252 TERMINAL-1/4 TAB, FEMALE, INSULATED

1

23 021257 TERMINAL-1/4 TAB, MALE, INSU-LATED

1

24 009502 HORN-24V 1

25 069478 SCREW-PHFHC, 1/4-20 X 3/4 1

26 504096 SUPPRESSOR ASSY-SPIKE, HORN

1

27 005640 CONNECTOR-PLUG, 16 SOCKET 1

28 504364 CLAMP & CLINCH NUT ASSY 1

29 — CABLE ASSY-PUMP MOTOR AND SOLENOID CABLES (FIGURE 12-28)

REF

30 — CABLE ASSY-CONTROL, HYDRAULIC (FIGURE 12-28)

REF

31 504097 SUPPRESSOR ASSY-SPIKE 1

32 023313 HARNESS ASSY-PUMP 1

33 005405 STRAIN RELIEF-3/8 1

34 020703 SWITCH-LIMIT, HIGH SPEED 1

35 077007 WASHER-FLAT, #6 2

36 023306 HARNESS ASSY-PST 1

37 — PANEL ASSY-ELECT (FIGURE 12-28)

REF


39 063552 SCREW-HX HD, 5/16-18 X 5/8 4

40 — SCALING CARD (FIGURE 12-28) REF

41 — WASHER-LOCK, SPLIT, #6 (FIGURE 12-28)

REF

42 — SCREW-SL RD HD, #6-32 X 1/2 (FIGURE 12-28)

REF

43 — BUSHING-INSULATING, NYLON (FIGURE 12-28)

REF

44 005678-01 HOUSING-SOCKET, 6 POSITION 1

45 005679 CONTACT-SOCT 4

— 003134 BATTERY-24V, 510AH, WET 1

— 506499-01 SPACER-BATTERY 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-45

Figure 12-28 Electric Panel Assembly

R6573

12-46 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 506570 PANEL ASSY-ELECT 1

1 403688 SHIM-CONNECTOR, BATTERY 1

2 506594-01 BATTERY CONNECTOR B& CABLE ASSY

1

3 075623-07 STUD-PRESS IN, 1/4-20 X 1-1/2 2


5 059421 NUT-HEX, 1/4-20 UNC 8

6 404995 PANEL-ELECTRIC 1

7 005473-01 AC CONTROLLER, MOTOR SPEED

1

8 075623-04 STUD-PRESS IN, 1/4-20 X 7/8 4

9 067430-02 SCREW-HX SOC HD, METRIC, M6 X 15 MM

5

10 503965-45 CABLE ASSY- #2 AWG, DRIVE MOTOR U

1

11 503965-45 CABLE ASSY- #2 AWG, DRIVE MOTOR V

1

12 503965-45 CABLE ASSY- #2 AWG, DRIVE MOTOR W

1

13 505858 CABLE ASSY-#2 AWG 1

14 070494 SCREW-PHRHC, #8-32 X 1/2 4

15 077205 WASHER-LOCK, SPLIT, #8 4

16 021263 TERMINAL-SINGLE SCREW, 5 PLC

2

17 021264 JUMPER-5 SCREW TERMINAL 2

18 023301 HARNESS ASSY-ELECT PANEL 1

19 023307 CABLE ASSY-LOWER CONTROL 1

20 023308 CABLE ASSY-CONTROL, HYDR 1

21 504857-11 CABLE ASSY-#2 AWG, TO PUMP MOTOR NEG

1

22 504857-11 CABLE ASSY-#2 AWG, TO PUMP MOTOR SOL POS

1


24 068230 SCREW-SLRHC, #6-32 X 3/8 5

25 059412 NUT-HEX, #6-32 UNC 4

26 075623-03 STUD-PRESS IN, 1/4-20 X 3/4 2

27 077031 WASHER-FLAT, 1/4 2

28 005691 SCALING CARD 1

29 404908 BRACKET-ROUND CONNEC-TOR, HARNESS

1

30 070489 SCREW-RHC, 1/4-20 X 5/8 BRASS 3

31 077045 WASHER-FLAT, 1/4 X 1/2 BRASS 2

32 008917 FUSE-40 AMP 1

33 056515 DECAL-FUSE (40 AMP) 1

34 010614 STANDOFF-INSULATOR 3

35 008906 FUSE-300 AMP 1

36 056507 DECAL-FUSE (300 AMP) 1

37 077105 WASHER-FLAT, 5/16 X 3/4 BRASS 1

38 023316-01 WIRE ASSY-18 AWG 1

39 008904 FUSE HOLDER 1

40 008910 FUSE-15 AMP, AGX TYPE 1

41 056504 DECAL-FUSE 1

42 023316-02 WIRE ASSY-18 AWG 1


44 068231 SCREW-SL RD HD, #6-32 X 1/2 2

45 403372 BUSHING-INSULATING, NYLON 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-47

Figure 12-29 Drive Motor

R6574

BRAKE KIT 901793 CONTAINS:

ITEM QTY2 13 14 15 1

CONNECTOR KIT 901794 CONTAINS:

ITEM QTY10 111 112 113 113 114 115 116 117 118 119 120 1

MOTOR KIT 901369 CONTAINS:

ITEM QTY22 123 124 125 126 127 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 016058 MOTOR-DRIVE, AC 1

1 901793 . BRAKE KIT 1

2 — . . BRAKE 1

3 — . . KEY 1

4 — . . SNAP RING 1

5 — . . SHIM RING 1

6 — . . SCREW 3

7 — . . STATOR 1

8 — . . ROTOR 1

9 901794 . CONNECTOR KIT 1

10 — . . WEDGE 1

11 — . . CONNECTOR 1

12 — . . SCREW-TAPPING 2

13 — . . PLATE-CONNECTOR 1

14 — . . NUT-HEX 3

15 — . . WASHER 3

16 — . . TERMINAL BOARD “U” 1

17 — . . TERMINAL BOARD “V” 1

18 — . . TERMINAL BOARD “W” 1

19 — . . SCREW-TAPING 3

20 — . . BOLT 3

21 901795 . SENSOR BEARING KIT 1

22 — . . CLIP 1

23 — . . RING 1

24 — . . SENSOR BEARING 1

25 — . . O-RING 1

26 — . . SPACER 1

27 — . . RING-SNAP 1

28 — END SHIELD, NON DRIVE SIDE 1

29 — RING 1

30 — SCREW 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-48 902998

Figure 12-30 Pump Motor

R1263

MOTOR KIT 901369 CONTAINS:

ITEM QTY10 112 116 119 1


INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 905053 . MOTOR ASSEMBLY 1

1 905055 . . COVER BAND 1

2 — . . SCREW 1

3 — . . NUT 1

4 905056 . . SCREW 4

5 905057 . . BOLT 4

6 — . . NUT 4

7 — . . LOCK WASHER 4

8 905058 . . HEAD, COMMUTATOR END 4

9 — . . SCREW 1

10 905059 * . . BRUSH SET, SERVICE 1

11 905060 . . PLATE ASSY, BRUSH 1

12 905061 * . . SPRING SET, BRUSH 1

13 905063 . . TERMINAL STUD PACKAGE 1

14 905064 . . FIELD COIL PACKAGE 1

15 905065 . . THRUST WASHER PACKAGE 1

16 905066 * . . BEARING, COMMUTATOR END 1

17 905067 . . ARMATURE 1

18 — . . SCREW 8

19 905068 * . . BEARING, DRIVE END 1

20 905069 . . HEAD, DRIVE END 1

* MOTOR KIT 901369

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-49

Figure 12-31 Key Switch

R6576

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 — PANEL ASSY-ELECT (FIGURE 12-28)

REF

2 056111 TIE-WIRE, NYLON SMALL 1

3 023316-03 WIRE ASSY-18 AWG, RED 1

4 020725 SWITCH-KEY 1

5 056689 DECAL-KEYSWITCH 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-50 902998

NOTES

902998 12-51

Figure 12-32 Remote Lift and Lower Schematic

R6575

12-52 902998

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 005649 CONNECTOR-SPLICE, TAP 2

2 021259 TERMINAL 1

3 023014 WIRE-STRAINDED, 18 GA, RED AR

4 017800 PLUG-FEMALE, FLUSH MOUNT 1

5 501736 REMOTE ASSY-PUSHBUTTON 1

6 068179 SCREW-SL RD HD, 5-40 X 5/8 2


8 059410 NUT-HEX, 5-0 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-53

Figure 12-33 Hour Meter/Battery Capacity Indicator

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 010628 GAUGE-COMBO 1

2 — . HARNESS (SUPPLIED WITH COMBO GAUGE)

1

3 023309 HARNESS ASSY 1

R6578

12-54 902998

Figure 12-34 Lift Limit Switch w/ Override

R6577

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 065476 SCREW-HEX HD,1/4-20 X 1/2 3


3 052947 BUSHING-RELIEF, STRAIN, 5/8 2

4 005311 CONDUIT-STEEL, THINWALL, 1/2 AR

5 004724 CORD-2 COND, 16 GA AR

6 021210 TERMINAL-FORK, INSUL, #6, 14-16 GA

2

7 056116 CLAMP-CABLE 3

8 063477 SCREW-HEX HD, 1/4-20 X 5/8 2

9 077031 WASHER-5/16 X 3/4 X 16 GA 2

10 005405 RELIEF-STRAIN, 3/8 1

11 020703 SWITCH-LIMIT 1

12 401921 BRACKET-MTG, SWITCH 1

13 101198 PLATE-SWITCH 1

14 067413 SCREW-PAN HD, #5-40 X 1/2 2

15 056557 DECAL-LIFT LIMIT OVERRIDE 1

16 020698 SWITCH-PUSHBUTTON, RED 1

17 021204 TERMINAL-RING, 3/16, 16 GA 3

18 021203 TERMINAL-RING, 3/16, 16 GA 1

19 023014 WIRE-STRAINED, 18 GA, RED AR

20 005679 CONNECTOR 1

21 — HYD CONTROL VALVE HARNESS REF

INDEXNO.

PARTNO. PART NAME

NO.REQD.

902998 12-55

NOTES

12-56 902998

Big Joe Manufacturing Company

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PDCE 40 - Big Lift, LLC Support Site for Big Joe Equipment · · 2008-11-04pdce 40 power driven counterbalanced electronic power steering ... brand control valve repair..... 9-5