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901630 i
TABLE OF CONTENTS - Continued
LIST OF FIGURES
ii 901630
LIST OF FIGURES - Continued
Figure Page Figure Page
9-16 Reach Cylinder ....................................................9-19 12-29 Control Valve to Lift Cylinder and Reach Cylinder
9-17 Reach Cylinder ....................................................9-20 (PDR 20 and 30 Full Free Lift)12-50
9-18 Tilt Cylinder.........................................................9-21 12-30 Reach Circuit..................................................... 12-52
9-19 Tilt Cylinder.........................................................9-22 12-31 Tilt Circuit ......................................................... 12-53
10-1 Single Pole Contactor, 2nd Speed, 3rd Speed Dynam- 12-32 Reach and Tilt Hoses......................................... 12-54
ic Brake10-1 12-33 Reach Cylinder.................................................. 12-55
10-2 Double Pole Contactor, Forward, Reverse ..........10-3 12-34 Reach Cylinder.................................................. 12-56
10-3 Electrical System Components ............................10-5 12-35 Tilt Cylinder ...................................................... 12-57
12-1 Control Head Assembly.......................................12-2 12-36 Tilt Cylinder ...................................................... 12-58
12-2 Control Head Pushbutton Switches .....................12-4 12-37 Lift Cylinder - Telescopic ................................. 12-59
12-3 Cold Conditioning, Control Head ........................12-5 12-38 Lift Cylinder - Trimast ...................................... 12-60
12-4 Steering Arm and Pivot Cap ................................12-6 12-39 Lift Cylinder - Trimast ...................................... 12-61
12-5 Pivot Tube Assembly...........................................12-8 12-40 Lift Cylinder - Trimast ...................................... 12-62
12-6 Brake and Linkage .............................................12-10 12-41 Lift Cylinder - Full Free Lift ............................. 12-63
12-7 Brake and Linkage .............................................12-12 12-42 Lift Cylinder - Full Free Lift ............................. 12-64
12-8 Transmission Assembly .....................................12-14 12-43 Remote Lift Hydraulics..................................... 12-65
12-9 Base and Frame..................................................12-16 12-44 Remote Lift and Lower Hydraulics................... 12-66
12-10 Decal Location ...................................................12-18 12-45 Remote Lift Schematic...................................... 12-67
12-11 Load Wheels ......................................................12-21 12-46 Remote Lift and Lower Schematic.................... 12-68
12-12 Telescopic Elevation System .............................12-22 12-47 Hydraulic Pump and Motor Assembly.............. 12-69
12-13 Trimast Elevation System ..................................12-24 12-48 12-Volt Pump Motor ......................................... 12-70
12-14 Full Free Lift Elevation System.........................12-26 12-49 12-Volt Pump Motor ......................................... 12-71
12-15 Trimast Staging Latch........................................12-29 12-50 24-Volt Pump Motor ......................................... 12-72
12-16 Reach Assembly ................................................12-30 12-51 Drive Motor....................................................... 12-73
12-17 One Piece Three Spool Valve Installation .........12-32 12-52 Drive Motor....................................................... 12-74
12-18 One Piece Valve Seal Kit...................................12-33 12-53 24-Volt Drive Motor ......................................... 12-75
12-19 Three Spool Stack Spool Valve Installation ......12-34 12-54 24-Volt Drive Motor ......................................... 12-76
12-20 Stack Spool Valve..............................................12-35 12-55 Electrical System Components.......................... 12-78
12-21 Stack Valve Switch ............................................12-36 12-56 12-Volt Contactor Panel.................................... 12-80
12-22 Stack Valve Seal Kit ..........................................12-36 12-57 24-Volt Contactor Panel.................................... 12-82
12-23 Reservoir, Pump and Control Valve Hoses (PDR 20 12-58 Speed Resistor Retrofit...................................... 12-84
Telescopic)12-38 12-59 Contactor, 2nd Speed, 3rd Speed,
12-24 Reservoir, Pump and Control Valve Hoses (PDR 30 Dynamic Brake.................................................. 12-86
Telescopic)12-40 12-60 Contactor, Forward, Reverse............................. 12-87
12-25 Reservoir, Pump and Control Valve Hoses (PDR 20 12-61 Battery Capacity Indicator Wiring Diagram
Trimast and Full Free Lift)12-42 Systems Without Lockout12-88
12-26 Reservoir, Pump and Control Valve Hoses (PDR 30 12-62 Battery Capacity Indicator Wiring Diagram
Trimast and Full Free Lift)12-44 Systems With Lockout12-89
12-27 Control Valve to Lift Cylinder and Reach Cylinder 12-63 Optional Hour Meter Installation for Resistor Trucks
(PDR 20 and 30 Telescopic)12-46 12-90
12-28 Control Valve to Lift Cylinder and Reach Cylinder 12-64 Optional Ignition Switch ................................... 12-91
(PDR 20 and 30 Trimast)12-48
LIST OF TABLES
Table Page Table Page
2-1 Operator Checks ............................................2-2 3-3 Lubrication Chart............................................3-3
2-2 Control Handles .............................................2-4 4-1 Troubleshooting Chart....................................4-1
3-1 Inspection and Service Chart .........................3-1 9-1 Trimast Lift Cylinders ...................................9-16
3-1 Recommended Lubricants and OIls...............3-2 9-2 FFL Lift Cylinders .........................................9-16
3-2 Hydraulic Oil Capacity Chart ..........................3-2
901630 iii
OPERATOR INSTRUCTIONS
WARNING
Do not operate this truck unless you have been trained Do not overload truck. Check capacity plate for load
and authorized to do so and have read all warnings weight and load center information.
and instructions in operator's manual and on this truck. When using forks, space forks as far apart as load will
Do not operate this truck until you have checked its permit. Before lifting, be sure load is centered, forks
condition. Give special attention to Tires, Horn, Lights, are completely under load, and load is as far back as
Battery, Controller, Lift System, (including forks or possible against load backrest.
attachments, chains, cables and limit switches),
Do not handle unstable or loosely stacked loads. Use
Brakes, Steering Mechanism, Guards and Safety
special care when handling long, high or wide loads to
Devices.
avoid losing the load, striking bystanders, or tipping
Operate truck only from designated operating position. the truck.
Never place any part of your body into the mast struc-
Do not handle loads which are higher than the load
ture or between the mast and the truck. Do not carry
backrest or load backrest extension unless load is
passengers.
secured so that no part of it could fall backward.
Observe applicable traffic regulations. Yield right of
Elevate forks or other lifting mechanism only to pick up
way to pedestrians. Slow down and sound horn at
or stack a load. Watch out for obstructions, especially
cross aisles and wherever vision is obstructed.
overhead.
Start, stop, travel, steer and brake smoothly. Slow Do not lift personnel except on a securely attached
down for turns and on uneven or slippery surfaces that specially designed Work Platform. Use extreme care
could cause truck to slide or overturn. Use special when lifting personnel. Make sure mast is vertical,
care when traveling without load as the risk of overturn place truck controls in neutral and apply brakes. Lift
may be greater. and lower smoothly. Remain in operating position or
Travel with lifting mechanism as low as possible. immediate vicinity as long as personnel are on the
Always look in direction of travel. Keep a clear view, Work Platform. Never transport personnel on forks or
and when load interferes with visibility, travel with load Work Platform.
or lifting mechanism trailing, except when traveling
Do not allow anyone to stand or pass under load or lift-
downhill.
ing mechanism.
Use special care when operating on ramps—travel
When leaving truck, neutralize travel control. Fully
slowly, and do not angle or turn. Travel with lifting
lower lifting mechanism and set brake. When leaving
mechanism or load downhill.
truck unattended, also shut off power.
Upon receipt, visually inspect the truck. If any damage Refer to “Battery Care” in Section 3 for battery check-
is found, report it to the carrier and to your Big Joe ing instructions.
dealer immediately.
Refer to SECTION 2 for operating instructions of
Remove cardboard banded to truck. Check lift truck for the brakes and lift control.
scratches and dents. Check to make sure that the lift
If you do not obtain the proper results, or if improper
chains are free of slack. Inspect for oil leaks and loose
operation occurs, refer to troubleshooting in SECTION
wiring connections. Make certain that all accessories
4.
and attachments that were ordered are supplied.
Before the lift truck is moved, the battery must be
checked, recharged if necessary, and connected.
iv 901630
SECTION 1
DESCRIPTION
R6209
901360 1-1
1-3. SAFETY FEATURES. 1-5. SAFETY SYMBOLS.
The PDR is designed and engineered to provide WARNING: This WARNING sign denotes a hazard. It
safety for operator and payload. Some of the safety calls attention to a procedure, practice or
features incorporated into the design are: the like, which if not correctly performed
Dead-man brake to apply mechanical brake and cut or adhered to could result in personal
off drive power when the steering arm is released. injury.
Belly-button switch to reverse truck should the opera- CAUTION: This CAUTION sign denotes a hazard. It
tor accidentally pin himself against a wall or obstruc- calls attention to a procedure, practice or
tion. the like, which if not correctly performed
High speed limit switch to restrict speed when lift car- or adhered to could result in personal
riage is raised above the preset limit. injury or damage to the equipment.
All control functions automatically return to “OFF” IMPORTANT:This heading calls attention to a proce-
when released. dure, which if not followed, may impede
the operation or normal flow of a servic-
Externally accessible quick-disconnect battery plug.
ing or repair procedure.
Separately fused control circuits and power circuits.
Readily accessible HORN button.
Lift carriage backrest to help stabilize the load.
Pressure compensated flow control valve regulates
maximum lowering speed.
High visibility color scheme of truck provides visual
alert of trucks presence.
1-2 901360
R3930
901360 1-3
NOTES
1-4 901360
SECTION 2
OPERATION
R3814
901360 2-1
2-3. BEFORE OPERATION proper lubrication, proper fluid levels,
brake maintenance, motor maintenance
Table 2-1 covers important inspection points on PDM
and other areas specified in the SEC-
lift truck which should be checked prior to operation.
TION 3.
Depending on use, some trucks may require additional
checks. WARNING: If the truck is found to be unsafe and in
Figure 2-2 shows a sample format for a Operator need of repair, or contributes to an
Checklist, which can be modified as necessary to fit unsafe condition, report it immediately to
your operation. the designated authority. Do not operate
it until it has been restored to a safe
WARNING: Periodic maintenance of this truck by a operating condition. Do not make any
QUALIFIED TECHNICIAN is required. unauthorized repairs or adjustments. All
service must be performed by a qualified
CAUTION: A QUALIFIED SERVICE TECHNICIAN
maintenance technician.
should check the truck monthly for
2-2 901360
R3814
901360 2-3
2-4. INSTRUMENTS AND CONTROLS. Table 2-2 Control Handles
2-4.1. Steering Arm and Control Head. SEE SUPPLEMENT 220 FOR TRANSISTOR
SPEED CONTROL TRUCKS.
The steering arm and control handle (See Figure 2-3)
provide controls for steering, forward and reverse Type Part Numbers.
speed control, braking, and horn. Control handles on Standard 505050-01
some models have pushbuttons for raising and lower- Remote Lift 505050-02
ing the forks. Table 2-2 lists optional control handles. in Handle
Controls handles on all models have a “belly-button” Remote Lift 505050-03
reversing switch which reverses the direction of the and Lower
truck upon contact with the operator. in Handle
R3974
2-4 901360
2-4.2. Lift/Lower Control. 2-4.5. Battery Disconnect.
The LIFT/LOWER control, Figure 2-4, is used to lift the A battery disconnect is mounted near the rear of the
forks and to regulate their lowering. The rate of rise is battery compartment. Pulling the disconnect removes
fixed, however, the descent of the forks is infinitely all power from truck circuits in the event of an emer-
variable. The farther the control lever is moved from gency.
neutral position, the faster the forks will descend.
2-4.6. Optional Features.
If the optional LIFT and LOWER pushbuttons on the
control handle or optional LIFT (UP) and LOWER The optional remote lift/lower control (if equipped)
(DOWN) remote control box are used, the lift carriage allows the operator to raise and lower the forks while
raises and descends at a fixed rate of speed. standing away from the control handle. See
Figure 2-5.
2-4.3. Reach Control. Other options are the battery capacity indicator, hour
The REACH control, Figure 2-4, is used to extend the meter and key switch, which mount on the panel near
forks forward toward the load. Pulling the REACH the control handle. The battery capacity indicator mon-
lever toward the operator retracts the reach assembly. itors the battery discharge rate to indicate the remain-
Pushing the control lever away from the operator ing battery capacity. The hour meter records the
extends the reach assembly. accumulated hours that electrical energy is being
drawn from the battery to run the pump and drive
2-4.4. Tilt Control. motors. The key switch provides added security to the
The TILT control, Figure 2-4, is used to tilt back the truck, preventing unauthorized personnel from operat-
angle of the forks. Pulling the control lever toward the ing the machine.
operator will cause the forks to tilt back. Pushing the
control lever away from the operator will cause the
forks to level.
R6539 R3962
Figure 2-4 Control Levers Figure 2-5 Optional Remote Lift/Lower Control
901360 2-5
2-5. OPERATION. There are four possible ways to stop the truck:
2-5.1. Forward and Reverse Travel and Speed 1. Plugging: This electrical braking function con-
Control. sists of rotating the speed control lever in the
opposite direction of travel and then releasing it
All directional and speed controls are located on the when the truck stops. Plugging is a convenient
control handle. See Figure 2-3. way to stop the truck during normal operation. If
Forward and reverse are controlled by rotating the the control is not released, the truck will acceler-
speed control lever as shown. The lever is spring ate in the opposite direction.
loaded to return to neutral when released. Further 2. Steering arm in horizontal position (See Fig-
rotation in either direction will progress the truck from ure 2-6): Lowering the steering arm to the hori-
slow to maximum travel speed. zontal position applies brake pad pressure to the
To change directions or to stop the truck, rotate the brake disc. Lowering the steering arm below the
speed control lever in the opposite direction. The truck horizontal position increases the braking force
will come to a stop and then, unless the controls are and de-energizes the controls.
returned to the center neutral position, accelerate in 3. Steering arm in vertical position (See
the opposite direction. Figure 2-6): Raising the steering arm to near ver-
tical position applies brake pad pressure to the
2-5.2. Steering. brake disc. Further vertical positioning increases
Moving the control handle (which connects to the the braking force and de-energizes the controls.
steering arm) right or left will turn the truck right or left. This position serves as a parking brake. As a
When maneuvering around corners, make square safety precaution, the steering arm is spring
turns and be sure there is adequate clearance. loaded to return to the vertical position in the
event the driver releases the control handle dur-
2-5.3. Stopping. ing operation. This is known as deadman braking.
Stop the truck as gradually as possible. Unnecessary
rapid stopping could be hazardous. Load could
become unstable.
R3929
2-6 901360
4. Dynamic brake: The dynamic brake serves as a 3. Raise forks to desired height for load entry.
secondary braking system completely indepen- 4. Move truck to align forks with pallet or skid as
dent from the mechanical brake. Pressing the close as possible.
dynamic brake pushbutton applies a constant DC
voltage across the drive motor field coils to stop 5. Extend lift carriage so forks are within pallet or
the motor. skid, and the load is centered over the forks and
as far back as possible.
CAUTION: The dynamic brake pushbutton should 6. Tilt lift carriage back, then raise forks to lift load.
not be held in place longer than one or
two seconds. Excessive use may blow 7. Slowly reverse the truck to move load free from
the 40 Amp fuse, which will render rack. When the load is clear, retract and lower the
dynamic brake inoperative. forks, leaving enough floor clearance to maneu-
ver truck.
2-5.4. Battery Charging
CAUTION: Drive the loaded truck slowly with fork
Refer to Document 245 for battery safety and tilted up, and use extra care when turn-
maintenance. ing.
901360 2-7
NOTES
2-8 901360
SECTION 3
PLANNED MAINTENANCE
3-1. GENERAL. charged (specific gravity 1.150 or less). This will also
Planned maintenance consists of periodic visual and greatly shorten battery life.
operational checks, parts inspection, lubrication, and 3-3.2. Battery Servicing.
scheduled maintenance designed to prevent or dis-
cover malfunctions and defective parts. The operator Refer to Document 245 for battery safety and
performs the checks in SECTION 2, and refers any maintenance.
required servicing to a qualified maintenance techni-
cian who performs the scheduled maintenance and
any required servicing.
3-3.1. General. The battery cells are accessed by opening the top
The life of the battery can be extended by giving it cover of the battery. Use the following procedure:
proper care. Perform a daily check of the battery 1. Obtain a battery hydrometer.
whether or not the equipment is in daily use. DO NOT
overcharge the battery or battery life will be shortened. NOTE: These can be obtained from a local hardware
DO NOT allow battery to become completely dis- store or automotive shop.
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check condition of drive motor commutator, brushes and springs
Monthly Check condition of pump motor commutator, brushes and springs
Monthly Check mechanical brake for proper operation
Monthly Check load wheels for wear
Monthly Check caster wheels for wear
Monthly Check drive wheel for wear
Monthly Inspect wiring for loose connections and damaged insulation
Monthly Inspect contactor tips for excessive pitting and wear
Monthly Check deadman brake switch for proper operation
Monthly Check lift chain tension, lubrication & operation (see paragraph 3-5.)
Monthly Lubricate Unit (See Table 3-3)
Quarterly Check lift cylinder for leakage
Quarterly Check for excessive jerking of steering arm when stopping or starting
Semi-annually Replace hydraulic filter assembly
Semi-annually Inspect for chain wear (See SECTION 8)
901630 3-1
4. Use the hydrometer to check specific gravity of Table 3-1 Recommended Lubricants and OIls
each cell
No. 1 Transmission oil—EP SAE 80W-90
NOTE: Battery specific gravity readings should agree Transmission oil—EP SAE 10W30 (Note)
within ± 0.025 from cell to cell. If variation is
Transmission oil capacity is 3 pints.
greater, the battery may have to be repaired
or replaced. No. 2 Grease—Lithium base, general purpose.
No. 3 Hydraulic oil-Heavy duty with a viscosity
CAUTION: Be sure that no cell plates are exposed of 150 SUS (in temperatures below 32 °F
(not covered by fluid) before charging. use 100 SUS) foam suppressing agent
Add distilled water sufficient to just cover and rust and oxidation inhibitors. See
top of cell plates. Table 3-2 for oil capacity.
CAUTION: Use distilled water. Impurities in tap Big Joe Part No. 900855 (1 gallon)
water will damage battery plates. 900893 (1 quart)
055784 (Note)
5. Charge battery as necessary. No. 4 SAE 30 or 40 engine oil
NOTE: A fully charged battery has a specific gravity NOTE: USED ON COLD CONDITIONED TRUCKS
of 1.260 to 1.275.
3-2 901630
R3929
901630 3-3
NOTES
3-4 901630
SECTION 4
TROUBLESHOOTING
4-1. GENERAL
1. SEE SUPPLEMENT 207 FOR CONTROL Table 4-1 serves as a guide to determine possible
HEAD ON TRANSISTOR TRUCKS causes of trouble. The table is divided into five main
SERIAL NUMBER 333423 TO 334630. categories: Truck dead: trouble with travel: trouble with
2. SEE SUPPLEMENT 220 FOR CONTROL braking: trouble with lifting or lowering, and Miscella-
HEAD ON TRANSISTOR TRUCKS neous malfunctions. Refer to electrical wiring diagram
SERIAL NUMBER 334631 AND HIGHER. (Figure 4-1) as a supplement to the troubleshooting
chart or when tracing an electrical circuit.
3. SEE SUPPLEMENT 187 FOR CONTROLLER
ON TRANSISTOR TRUCKS
SERIAL NUMBER 333423 TO 334630.
4. SEE SUPPLEMENT 221 FOR CONTROLLER
ON 12 VOLT TRANSISTOR TRUCKS
SERIAL NUMBER 334631 TO 372951, EXCEPT
363937, 363938, AND 372827.
5. SEE SUPPLEMENT 221 FOR CONTROLLER
ON 24 VOLT TRANSISTOR TRUCKS
SERIAL NUMBER 334631 TO 374310.
6. SEE SUPPLEMENT 364 FOR CONTROLLER
ON 12 VOLT TRANSISTOR TRUCKS
SERIAL NUMBER 363937, 363938, 372827
AND 372951 AND HIGHER.
7. SEE SUPPLEMENT 348 FOR CONTROLLER
ON 24 VOLT TRANSISTOR TRUCKS
SERIAL NUMBER 374311 AND HIGHER.
901630 4-1
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH TRAVEL Check all wiring. A loose connec- Tighten all loose connections before fur-
tion may be the cause of malfunc- ther troubleshooting.
tion.
Truck does not run forward or a. 15-Amp control circuit fuse Check fuse and replace if defective.
reverse. Everything else is blown.
normal.
b. Defective key switch Bypass keyswitch to determine if it is mal-
functioning.
c. Shorted dynamic brake switch Check brake switch and contactor and
or dynamic brake contactor. replace if defective.
d. Defective dead-man brake Check and replace if required.
switch.
e. Main wire harness cut. Replace.
f. Belly button switch defective. Replace.
Truck runs forward, but not in a. Defective speed control switch Check for positive DC voltage at number
reverse. or defective contactor. 1-wire on reverse contactor. If not present
when steering arm is in operating position
and speed control is in reverse, speed
control switch is defective. If voltage is
present, contactor is defective.
b. Belly button switch out of Adjust or replace.
adjustment or defective.
Truck runs in reverse, but not Defective speed control switch or Check for positive DC voltage at number 2
in forward. defective contactor. wire on forward contactor. 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.
Truck runs forward and in a. Third speed cutout switch out Adjust or replace.
reverse at slow speed; will not of adjustment or defective.
run at higher speeds.
b. Defective second and/or third Check coils for continuity. Check contacts
speed contactors. for excessive wear. (A black appearance
where tips make contact is normal). Repair
or replace as required.
c. Defective optional time delay Check for continuity and replace as
relay(s). required.
Truck runs forward and in Defective or open speed control Check for clean, tight connections. Check
reverse at second or third resistor. resistor for continuity and replace or repair
speed only. Truck does not as required.
move when control is in first
speed position. Everything
else is normal.
Truck runs at second or third a. Defective 2nd or 3rd speed Check for shorted contacts on 2nd or 3rd
speed when control is in the contactor. speed contactor.
first speed position. Every-
b. Defective speed control Check switches.
thing else is normal.
switch.
c. Shorted speed control resistor. Check wiring of resistor.
4-2 901630
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH BRAKING
Mechanical brake does not a. Brake linkage in need of Adjust mechanical brake (see paragraph
stop truck properly. adjustment. 6-2.).
b. Disc brake pads worn. Replace pads and readjust mechanical
brake.
Mechanical brake grabs when Brake linkage over adjusted. Adjust mechanical brake (see paragraph
steering arm is in operating 6-2.).
position.
Dynamic brake does not stop a. 40-Amp fuse blown. Check and replace fuse.
truck.
b. Defective brake switch, brake If click is heard when dynamic brake push-
relay, or brake resistor. button is pressed, check brake resistor
and relay contacts. If no click, check brake
switch and coil of relay. Repair or replace
defective part.
TROUBLE WITH LIFTING Oil level too low. Check hydraulic oil level. Fill hydraulic res-
OR LOWERING 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 and a. Defect in electrical system. a. If pump motor does not run when LIFT
extend, Retract and Tilt do not control is in UP position or Extend,
function; everything else is Retract, and Tilt are operated, defect is
normal. 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 spool 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; Control valve defective or defect in Check control valve for proper action.
everything else is normal. hydraulic system. Check for obstruction in the hydraulic line.
Repair as required.
Forks creep downward under Leak in hydraulic system, packing, Look for loose fittings in the hydraulic line,
load; everything else is nor- control valve, or pump. pump for leakage back into the reservoir
mal. and oil on top of packing. Repair fittings or
replace pump as required. Replace pres-
sure relief valve.
Oil sprays or flows from the Defective packing in lift cylinder. Overhaul the lift cylinder and install new
top of the lift cylinder. packing, seal, and wiper ring.
Oil foaming in vent for hydrau- Leak in the suction line between Check oil filter. Replace if necessary.
lic reservoir. the pump and the reservoir. Tighten fitting. Inspect line and replace if
necessary.
901630 4-3
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Oil splashes out of vent when Oil level too high. Drain, then refill reservoir when lift car-
lowering forks. riage is in the lowest position.
Squealing sounds when forks a. Oil level too low. Add oil to reservoir.
are raised.
b. Dry channels in mast. Apply grease.
c. Defective bearing. Replace bearing.
Forks do not lift to top. Pump a. Oil level too low. Add oil to reservoir.
motor runs.
b. Load heavier than capacity. Refer to nameplate for maximum load
capacity.
c. Defective pump or motor. Replace.
Oil leaks at throttle valve Defective O-rings in throttle valve Replace O-rings around release cam.
release cam. body.
Control valve spring- centered a. Broken springs. Replace springs.
handle does not return to neu-
b. Foreign particles. Clean system and valve.
tral.
c. Misalignment of operating link- Check linkage for binding condition.
age.
Load drops when LIFT control a. Dirt or foreign particles lodged Disassemble, clean and reassemble.
is moved from neutral to UP between check valve poppet
position. and seat.
b. Scored check ball. Replace check ball.
c. Defective check ball seat in Lap new check ball body seat.
valve body.
No motion, slow or jerky a. Load heavier than capacity. Refer to nameplate for maximum lift
action of hydraulic system. capacity.
b. Defective lift cylinder. Rebuild or replace.
MISCELLANEOUS
Steering arm does not return a. Return spring improperly Readjust spring tension (see paragraph
to the upright position. adjusted. 5-6.).
b. Binding brake linkage or elec- Check and free the binding item.
trical cable.
c. Broken spring Replace.
Truck moves forward in low a. Belly-button reversing switch Check for short, and repair or replace as
speed when arm is pulled defective. necessary.
down.
b. First speed forward switch Replace.
defective.
c. Forward contactor stuck Repair or replace.
closed.
Steering arm jerks excessively a. Worn pivot tube bushings. Replace upper and lower pivot tube bush-
when starting or stopping the ings.
truck.
b. Drive tire worn or mounted Repair or replace.
incorrectly.
4-4 901630
NOTES
901630 4-5
R6210A
4-6 901630
R6210B
901630 4-7
NOTES
4-8 901630
SECTION 5
STEERING ARM AND CONTROL HEADS SERVICING.
The following procedures cover adjustments, replace- 2. SEE SUPPLEMENT 220 FOR CONTROL
ment, and repair of the steering arm, control head, and HEAD ON TRANSISTOR TRUCKS
related assemblies and components. The procedures SERIAL NUMBER 334631 AND HIGHER.
are independent of each other unless specifically
referenced.
R1094
901630 5-1
5-3. BELLY-BUTTON SWITCH ADJUSTMENT.
1. Disconnect battery.
CAUTION: While removing the belly-button casting,
two springs (needed for reassembly) will
fall free.
3. Bend actuator lever of belly-button switch (Figure Figure 5-3 Belly-Button Switch Adjustment
5-3) to adjust gap so that switch clicks half way
through travel of casting. 5-4. CONTROL HEAD SWITCH REPLACEMENT.
4. Reinstall casting, making certain all parts are back NOTE: Refer to paragraph 5-5. for speed control
in place. switch replacement.
5. Check operation of the belly-button switch by
pressing the belly-button casting while listening NOTE: For access to belly-button switch, see para-
for the “click” that indicates that the switch has graph 5-3. For access to other switches on
actuated. control head, the top cover (15, 16, or 17, Fig-
ure 5-5) and/or switch plate (18) must be
NOTE: The click should be heard when the belly-but- removed.
ton casting has moved about 50 per cent of
its normal travel distance. If the click is heard NOTE: All electrical connections should be tagged
at the beginning of travel, the switch may with identifying labels before disconnecting.
actuate at inappropriate times. If the click is 1. Disconnect battery.
heard near the end of travel, the switch could
be unreliable and may not actuate in some 2. If necessary to gain access to defective belly-but-
instances. ton switch, remove belly-button casting (42, Fig-
ure 5-4) by performing step 2. in paragraph 5-3.
6. Repeat steps 2. through 5. until pressing the 3. Remove top cover (15, 16, or 17, Figure 5-5) by
belly-button casting actuates the switch properly. removing four screws (14).
7. Reconnect battery and electrical connections. 4. Remove switch plate (18) by removing four
WARNING: Testing of belly-button switch in opera- screws (15 and 16, Figure 5-4) on top and bottom
tion should be limited to areas clear of of control handle (41).
obstacles against which an operator 5. Replace belly-button switch (3), speed control
could be pinned. Use first speed, switches (4), horn switch (4, Figure 5-5), or lift,
reverse. lower and dynamic brake switches (3).
5-2 901630
1. SEE SUPPLEMENT 207 FOR CONTROL
HEAD ON TRANSISTOR TRUCKS
SERIAL NUMBER 333423 TO 334630.
2. SEE SUPPLEMENT 220 FOR CONTROL
HEAD ON TRANSISTOR TRUCKS
SERIAL NUMBER 334631 AND HIGHER.
R3837
901630 5-3
SEE SUPPLEMENT 207 AND 220 FOR
TRANSISTOR SPEED CONTROL TRUCKS
R5215 R5217
R5216 R5218
5-4 901630
4. Remove four screws (14, Figure 5-5) and top 5-6. STEERING ARM RETURN SPRING
cover (15, 16 or 17). ADJUSTMENT.
5. Disconnect speed control switches (4, Figure 5- The tension on the steering arm return spring should
4). allow the steering arm to return gently to the upright
6. Remove four screws (17) securing handle guard position. Excessive tension on the steering arm return
(36) to control head. spring will cause the steering arm to snap up and may
cause damage to the electrical cable, brake linkage, or
7. Remove two socket head screws (18) and caps
the spring itself. If the steering arm does not return
(29) from handle guard (36).
fully, check for binding in the brake linkage or wiring
8. Remove handle guard with two brackets (33 and harness before making any adjustments. If they do not
39) and speed control switches (4) attached. bind, refer to Figure 5-6 and proceed as follows to
9. Remove roll pin (10) from right hand handle grip adjust the steering arm return spring tension.
(31). 1. Disconnect the battery.
10. Remove right hand handle grip from shaft (28). 2. Hold the steering arm (13, Figure 5-6) in the
11. Remove set screw (22) from right hand control upright position and make sure the arm cannot
lever (40). fall.
12. Remove right hand control lever from tube (34). 3. Insert a 5/16 allen wrench through hole in bottom
of steering arm and loosen screw (1). The spring
13. Observing through top cover opening, slide shaft
tube (4) will rotate counterclockwise when screw
(28) with tube (34) out left hand side of control
is loosened.
head just enough to clear return spring (24).
4. With a pair of vise grip pliers, grip the flat surfaces
14. Disengage return spring from spiral pin (12) and
of the spring tube assembly (4) and rotate clock-
remove return spring.
wise 180 degrees.
15. Place new return spring in position, engage with
5. Hold spring tube assembly in rotated position and
spiral pin, and slide shaft (28) with tube (34) back
tighten screw (1) to secure.
through return spring and out right hand side of
control head. 6. Check the spring action by lowering the steering
arm and returning it to the upright position two or
16. Install right hand control lever (40) onto tube (34),
three times.
and secure with set screw (22).
7. If necessary, repeat steps 2. through 6., increas-
17. Install right hand handle grip (31) onto shaft (28),
ing or decreasing amount of rotation of the spring
align roll pin hole in handle grip with roll pin hole in
tube assembly until steering arm returns gently to
shaft, and install roll pin (10).
full upright position.
18. Install handle guard (36), with two brackets (33
8. Reconnect battery.
and 39) and switches (4) attached, and secure
with two caps (29) and screws (18).
5-7. STEERING ARM RETURN SPRING
19. Install four screws (17) through handle guard and REPLACEMENT.
into control head.
NOTE: The steering arm return spring is replaced
20. Reconnect speed control switches (4).
while the steering arm is in the upright posi-
21. Install top cover (15, 16 or 17, Figure 5-5) with tion.
four screws (14).
1. Disconnect battery.
22. Reconnect the control cable connector to the con-
trol head. NOTE: The steering arm has a tendency to fall down-
23. Install control head onto steering arm with the four ward when the tension on the return spring is
socket head screws. released.
24. Reconnect battery. 2. Hold steering arm (13, Figure 5-6) in upright posi-
tion and make sure the arm cannot fall.
3. Insert a 5/16 allen wrench through hole in bottom
of steering arm and loosen screw (1).
901630 5-5
HANDLE RETURN SPRING
KIT 901325 CONTAINS:
ITEM QTY
4 1
5 1
6 1
7 1
14 1
15 1
25
22
17
R5994 R5384
5-6 901630
CAUTION: Unless properly supported, steering arm 15. Reconnect battery.
will drop out of pivot cap when spring
tube is removed. 5-8. PIVOT TUBE AND FLANGED BUSHING
REPLACEMENT.
4. Put a block under steering arm at pivot cap.
5. With a piece of chalk or crayon, draw a straight NOTE: All electrical connections and cabling should
line from center of spring tube assembly (4) into be tagged with identifying labels before dis-
pivot cap (17), marking radial position of tube, to connecting.
facilitate reinstallation. NOTE: A chain hoist is required for this procedure. It
6. With a pair of vise-grip pliers, grip the flat surfaces should be in position above the pivot tube
of spring tube assembly (4), and slowly pull it free before disassembly.
from the steering arm, pivot cap and tube clamp
(16). 1. Remove the transmission as described in
SECTION 7.
NOTE: Steering arm return spring (5) will remain 2. Position a support under pivot tube.
inside the spring tube assembly (4).
3. Remove the cotter pin and clevis pin (9, Figure 5-
7. Remove steering arm return spring (5) from 6) and disconnect clevis (12) from the brake
spring tube assembly (4). If spring is severely upper pivot. Refer to Figure 5-8.
jammed and will not come loose, punch and drive 4. On trucks serial numbers 333423 to 346936
the 1/4-inch diameter roll pin into the tube. Save except 346722, 346751, 346927, 346935:
pin for reuse. Remove the spring. Tap roll pin remove two socket head screws (25, Figure 5-
back into place. 6) securing pivot cap cover.
8. Lubricate the ends and outer surface of the new 5. Remove pivot cap cover (22, Figure 5-6).
steering arm return spring (5) with a lithium base
general purpose grease. 6. Remove electrical control cable, steering arm and
control head from pivot tube assembly.
9. Insert spring into spring tube assembly and press
in, making sure that one spring loop eye fits over 7. On trucks serial numbers 346722, 346751,
the 3/8-inch roll pin at the closed end of the spring 346927, 346935 346937 and higher: Remove
tube assembly. snap ring (23) and pin (24).
10. Slide spring tube assembly into pivot cap (17) and 8. Remove pivot cap (17) and spacer (1, Figure 5-8).
steering arm (13) through tube clamp (16) and 9. Position a chain hoist above the pivot tube.
through loop of electrical cable. 10. Connect chain to pivot tube as follows:
11. Align radial position of spring tube assembly in a. For trucks serial numbers 333423 to
accordance with line drawn in step 5. Slowly 346936 except 346722, 346751, 346927,
rotate spring tube assembly a few degrees each 346935: use the two pivot cap cover screws
way until the steering arm return spring snaps into as a means of attachment for the chain hoist.
place over spring pins (14 and 15) then tighten Secure the chain hoist to the pivot tube.
screw (1).
b. For trucks serial numbers 346722, 346751,
12. Apply engine lubricating oil (No. 2) to the steering
346927, 346935 346937 and higher: Use
arm elbow.
tool kit part number 907151. Position
13. Remove block from under steering arm. spacer, Figure 5-7, inside the pivot tube.
14. Adjust tension on steering arm return spring as Insert the pin through the spacer and secure
explained in paragraph 5-6. with the cotter pin. Attach the chain hoist to
the spacer.
901630 5-7
18. Install bushing (10) with screws (9).
19. Install bushing (4).
20. Position upper bushing (4), spacer (2), bearing
(5), support (6), and lower bushing (10) into the
pivot weldment and route hoist chain through
these parts.
21. Position the pivot tube under the pivot weldment
and attach hoist chain to pivot tube as described
in Step 10.
22. Raise the pivot tube into position.
23. Position upper bushing (4) on the upper pivot
flange with the roll pin (3) aligned with the bushing
roll pin cutouts.
R5432
24. Position spacer (2), bearing (5) and support (6),
Figure 5-7 Pivot Tool Removal Tool below the upper bushing (4) and attach support
11. Remove cotter pin (7, Figure 5-8) from pin (8), (6) to pivot tube with spring support pin (8).
then remove pin (8) from upper spacer (6). 25. Secure spring support pin (8) with cotter pin (7).
12. Remove the support from under the pivot tube 26. Remove hoist chain and the two pivot cap cover
and remove the pivot tube from the bottom of the screws or pivot tube tool as applicable.
truck. 27. Position the lower bushing (10) on the lower pivot
13. Disconnect the chain from the pivot tube and flange with the screw holes in the flange aligned
remove support (6), bearing (5), ring (2) and with the cutouts in bushing (10).
bushing (4). 28. Install thee screws (9).
14. Remove three screws (9) securing bushing (10).
CAUTION: Be sure to observe cable routing and
15. Remove lower pivot bushing (10). positioning when reinstalling electrical
16. Inspect the bearing (5) for wear. If worn, replace control cable to prevent cable damage.
with new bearing.
29. Reinstall steering arm onto pivot tube, being care-
17. Discard the two old bushings (4 and 10). ful not to damage electrical control cable while
NOTE: When installing the new parts, refer to Figure routing it through the pivot tube. (See Figure 5-9).
5-8 to be sure they are positioned on the pivot 30. Install pivot cap cover.
tube in the proper order. 31. Install the transmission as described in SECTION
7.
5-8 901630
R3942
901630 5-9
5-9. ELECTRICAL CONTROL CABLE 13. Check that the other wire from the deadman
REPLACEMENT. switch is connected to terminal 3.
1. Disconnect battery. 14. Route connector (8) end of cable under spring
tube assembly (3) and out the opening at the
NOTE: When removing control head in the following elbow.
step, be sure to hold it in place until cable is
15. Eliminate cable slack in pivot tube (10), then
disconnected.
secure cable with cable clamp (1).
2. Remove four screws (7, Figure 5-9) that secure
control head to steering arm. CAUTION: Improper cable loop adjustment while
performing the following step will dam-
3. Disconnect connector (8), and set aside control age the cable. If too tight, the cable will
head. tear when the steering arm is in the up
4. Use Amp Extraction Tool part number 900750 to position. If too loose, the cable will
push out and disconnect wire pins from connector buckle or be pinched when the steering
(8). arm is in the down position.
5. Remove cable clamps (1, 2) and loosen loop of 16. Loop cable around spring tube assembly (3) as
cable that surrounds the spring tube assembly illustrated and push connector (8) end of cable
(3). through steering arm.
6. Remove pivot cap cover (6). 17. Pull the cable until the cable is wrapped firmly
7. Pull disconnected end of old cable through steer- around the spring tube assembly (3). Slack off
ing arm and pivot cap, then up through pivot cap approximately 1/2 inch and secure the cable in
cover opening. this position with cable clamp (2).
8. Tape the disconnected end of the old cable to the NOTE: Movement of the electrical cable in the steer-
terminal end of the new cable. ing arm of some lift trucks may occur, result-
NOTE: The dead-man switch is on the brake linkage. ing in stretching and/or breaking of the cable.
The wire connected to pin number 3 on the This problem usually occurs only in trucks
terminal board (9) is a wire that comes from without the LIFT and LOWER pushbuttons.
the dead-man switch. Cable wire number 3 is These trucks use a smaller diameter 8-con-
connected to the other lead on the dead-man ductor cable whereas trucks with the LIFT
switch. and LOWER pushbuttons use a 12-conductor
cable.
9. Remove base access cover, and disconnect ter-
minal end of old cable from transmission terminal Big Joe recommends that the existing 5/8-
board (9) and cable wire number 3 from deadman inch diameter cable clamps, part number
switch lead. 502474, be replaced with the new 9/16-inch
10. Draw new cable into pivot tube by pulling old cable clamps, part number 504364, on trucks
cable through the base access opening. using the 8-conductor cable.
5-10 901630
1. CABLE CLAMP
2. CABLE CLAMP
3. SPRING TUBE ASSEMBLY
4. ELECTRICAL CONTROL CABLE
5. PIVOT CAP
6. PIVOT CAP COVER
7. CAP SCREWS
8. FEMALE CONNECTOR
9. TERMINAL BOARD
10. PIVOT TUBE
11. TRANSMISSION HOUSING
R962, R963
901630 5-11
NOTES
5-12 901630
SECTION 6
BRAKE SERVICING
R3629
901630 6-1
6-2.2. Trucks Serial Number 333423, 333641 AND
HIGHER.
USED ON TRUCKS SERIAL
NUMBERS 324266 TO 333640, 1. Disconnect battery connections.
EXCEPT 333432 2. Securely block the truck to prevent slipping, then
jack up the truck so the drive wheel is off the
ground.
3. Remove service cover.
4. Secure steering arm assembly in a position that is
in either lightly shaded area shown in Figure 6-1.
5. Remove the cotter pin (1, Figure 6-3), and pin (2)
to disconnect the clevis (3) from the lever assem-
bly.
6. Loosen the lock nut (4).
6-2 901630
12. Secure the steering arm in drive position and spin 7. Insert replacement brake pads in clamp assem-
the drive wheel to make sure there is no drag. If bly, one pad on each side of disc (31) with linings
there is any drag, carefully readjust only enough towards the disc, and secure pads and clamp with
to eliminate drag in the drive position. two bolts (25) and nuts (26). Be sure spring (37) is
13. Tighten the lock nut (4) and secure the pin (2) with installed between pads.
the cotter pin (1). 8. Release steering arm.
14. Remove the restrictions from the steering arm 9. Refer to paragraph 6-2. and adjust brake.
and let the arm return to the upright position. 10. Reconnect battery connections.
15. Check that the brake lever has activated the
dead-man brake switch and open the control cir- 6-3.1.2. Brake Lever
cuits. If the switch is not activated, go to step 16. If 1. Disconnect battery connections.
it is activated, go to step 18.
2. Block the wheels to prevent the truck from rolling.
16. Adjust the position of the dead-man switch by
3. Position the steering arm to the left as far as pos-
loosening the screws attaching the switch to the
sible, and secure the steering arm down from its
mounting bracket, then sliding the switch in or out
park position so that the mechanical brake is dis-
in the adjustment slots, and tightening the screws.
engaged.
17. Make sure that applying the brake activates the
4. Remove service cover.
switch but does not fully depress the switch
plunger. If necessary, repeat steps 15. and 16. NOTE: The brake lever (23, Figure 6-4) has a pin
until the switch is properly positioned. that fits into one of two slots on the inside of
18. Lower the truck and install the service cover. the clamp assembly.
19. Reconnect battery connections. 5. Check position of lever inside the clamp assembly
20. In an area free of obstructions, accelerate the so that you will be sure to place brake lever pin in
truck and apply the brake. Check for proper oper- correct slot during reassembly.
ation in both forward and reverse. 6. Release brake lever (23) from weldment tube (20)
by removing cotter pin (19) from weldment tube
6-3. REPLACEMENT OF DISC BRAKE PARTS stub.
6-3.1. Trucks Serial Number 333432 TO 333640 NOTE: The brake pads (24) and springs (37) may fall
EXCEPT 333432 free during the next step.
6-3.1.1. Disc Brake Pad 7. Remove two bolts (25) and nuts (26) to release
brake clamp (22) from mounting plate (27).
1. Disconnect battery connections.
2. Block the wheels to prevent the truck from rolling. 8. If brake pads did not fall free, slide the brake pads
(24) out from end of clamp and slide the brake
3. Position the steering arm to the left as far as pos- lever (23) out through the brake lever access hole
sible, and secure the steering arm down from its located on the opposite side of the clamp.
park position so that the mechanical brake is dis-
9. Check that replacement brake lever (23) has pin
engaged.
tightly secured.
4. Remove service cover.
10. Slide the brake lever (23) in through the brake
NOTE: The brake pads may fall free during the next lever access hole located on the opposite side of
step. the clamp and align the brake lever so that the pin
is in the proper pin slot.
5. Remove two bolts (25, Figure 6-4) and nuts (26)
to release brake pads (24). 11. Slide clamp (22) on mounting plate is at lever side
of clamp, reinstall brake pads (24), one pad on
6. If brake pads don’t fall free, slide brake pads out each side of disc (31) with linings toward the disc,
from end of clamp (22). and check that pin in lever is in proper slot of the
clamp.
901630 6-3
12. Secure clamp to mounting plate with two bolts position so that the mechanical brake is disen-
(25) and nuts (26). Be sure springs (37) are gaged.
installed. 4. Remove the service cover.
13. Insert stub of weldment tube (20) up throu hole in 5. Remove two bolts (25, Figure 6-4) and nuts (26)
brake lever (23) and secure with cotter pin (19). to release brake pads (24).
14. Adjust brake as described in paragraph 6-2.. 6. If brake pads don’t fall free, slide pads out from
15. Reconnect battery connections. end of clamp (22).
6-3.1.3. Brake Disc. 7. Remove nut (33) and lock washer (32).
8. Remove the disc assembly (31).
1. Disconnect the battery.
9. Remove key (30).
2. Block the wheels to prevent the truck from rolling.
10. Install new disc assembly with key (30), lock
3. Position the steering arm to the left as far possible
washer (32) and nut (33).
and secure the steering arm down from its park
R357
6-4 901630
11. Insert brake pads in clamp assembly; one pad on 16. Engage the clevis (13) with the lever (39), then
each side of disc (31) with linings toward the disc, insert the pin (7) and secure it with the cotter pin
and secure pads and clamp with two bolts (25) (2).
and nuts (26). Be sure spring (37) are installed 17. Remove the restrictions from the steering arm.
between pads.
18. Adjust the brake as described in paragraph 6-2.
12. Remove restrictions from the steering arm.
19. Install the base access cover.
13. Adjust brake as described in paragraph 6-2.
20. Reconnect battery connections.
14. Reconnect the battery.
6-3.2.2. Replacement of Brake Disc.
6-3.2. Trucks Serial Number 333432, 333641 AND
HIGHER 1. Disconnect the battery.
2. Block the wheels to prevent the truck from rolling.
6-3.2.1. Disc Brake Pad
3. Remove the base access cover.
1. Disconnect battery connections.
4. Position the steering arm to the left as far as pos-
2. Block the wheels to prevent the truck from rolling. sible, and secure the steering arm down from its
3. Position the steering arm to the left as far as pos- park position so that the mechanical brake is dis-
sible, and secure the steering arm down from its engaged.
park position so that the mechanical brake is dis- 5. Remove the cotter pin (2, Figure 6-5) and pin (7),
engaged. then swing the clevis (13) up out of the way.
4. Remove service cover. 6. Remove the two nuts (28) and lock washers (29).
5. Remove the cotter pin (2, Figure 6-5) and link pin 7. Carefully pull the bolts (30) just enough to clear
(7), then swing the clevis (13) up out of the way. the mounting plate weldment (17) while you hold
6. Remove two nuts (28) and lockwasher (29). together the remaining parts of the disc brake
7. Carefully pull the bolts (30) just enough to clear assembly (27), then remove the assembly.
the mounting plate weldment (17) while you hold 8. Remove the nut (21) and lock washer (20).
together the remaining parts of the disc brake 9. Remove the disc assembly (19).
assembly (27), then remove the assembly.
10. Remove the key (18).
8. Remove the bolts (30), spacers (31), springs (32),
11. Install new disc assembly with key (18), lock
and brake pad (33).
washer (20) and nut (21).
9. Remove the retaining C-ring (34), washer (35),
12. Assemble the brake pad (33), springs (32), and
spring (36), bracket (38), lever (39), and washer
spacers (31) to the two bolts (30).
(40) from the brake pad (37).
10. Discard the springs (32 and 36) and brake pads 13. Slip brake pad (37) with attached parts onto the
(33 and 37). Replace them with new parts. mounting plate weldment (17) and hold it so the
bolt holes are aligned.
11. Assemble the washer (40), lever (39), bracket
14. Insert the bolts (30) through the pad (37) and
(38), spring (36), washer (35), and C-ring (34) to
bracket (17), so the threaded portion of the bolts
the brake pad (37).
passes completely through.
12. Assemble the brake pad (33), spacers (31), and
15. Assemble the two lock washers (29) and nuts (28)
springs (32) to the two bolts (30).
to the bolts (30).
13. Slip the parts assembled in step 11. onto the
mounting plate weldment (17) and hold them so 16. Engage the clevis (13) with the lever (39), then
the bolt holes are aligned. insert the pin (7) and secure it with the cotter pin
(2).
14. Insert the bolts (30) through pad (37) and bracket
17. Remove the restrictions from the steering arm.
(17), so the threaded portion of the bolts passes
completely through. 18. Adjust brake as described in paragraph 6-2.
15. Assemble the two lock washers (29) and nuts (28) 19. Install the service cover.
to the bolts (30). 20. Reconnect the battery.
901630 6-5
USED ON TRUCKS SERIAL
NUMBERS 333432 AND
333641 AND HIGHER
R3297
6-6 901630
SECTION 7
TRANSMISSION, DRIVE WHEEL CASTER WHEEL AND LOAD WHEEL SERVICING
R4702
901630 7-1
TRUCKS SERIAL NUMBERS 333432, 333641 AND HIGHER
ALL TRUCKS
R4702
7-2 901630
12. Remove the four screws (5) and washers (6) that 23. Refer to the disassembly instruction as a guide,
secure the transmission (7) to the pivot tube weld- and reverse the individual procedures to reas-
ment (8). semble and reinstall the transmission.
13. Remove the transmission and drive wheel (9) NOTE: When reassembling, be sure to replace the
from the truck by raising the rear of the lift truck gasket and reinstall the magnetic drain plug
with jacks or other suitable means and sliding the before refilling the transmission with trans-
assembly out from under the truck. mission oil. Transmission oil capacity is 3
14. Remove the four hex head cap screws (22, Figure pints.
7-1) and lock washers (23), bearing cover (21)
and gasket (20). 24. Fill the transmission to fill plug level with EP SAE
80W-90 automotive transmission oil.
15. Remove bearing spacer (15).
16. Remove seven screws (19), two screws (25), and 7-2. DRIVE WHEEL REPLACEMENT
lock washers (18); pry off transmission cover (17)
1. Disconnect battery.
and pull off cover gasket (16).
2. Securely block the load wheels to prevent the
17. Remove ball bearing (14) and pinion spacer (13).
truck from moving.
18. Remove intermediate gear (12) and square key 3. Remove base access cover.
(10).
4. Use a jack to raise the rear of the lift truck so that
19. Remove spur pinion (11).
the drive wheel clears the ground.
20. Remove locknut (8) and lock washer (7).
5. Lower the truck on blocks, making certain the
21. Remove drive wheel and axle shaft (1) to free drive wheel is still clear of the ground.
gear (6), roller bearing cones (3) and cups (4), 6. Remove the five retaining screws (36, Figure 7-1)
and oil seal (2). and lock washers (35) that secure the drive wheel
22. Remove ball bearing (9). to the axle shaft and then pry off the wheel.
7. Reverse the above procedures to install new drive
wheel. Torque screws (36) to 115-125 ft.-lbs.
901630 7-3
7-3. LOAD WHEELS. 5. Remove the snap ring (1, Figure 7-3), securing
the load wheel axle (2).
1. Unload the truck and block the drive wheel.
2. Disconnect battery. 6. Remove axle. Load wheel (5) will drop free, along
with two washers (4), one on each side, which
3. Raise the front of the lift truck with a jack or position wheel on axle.
another lift truck and place supporting boards or
7. Remove bearing (6) and check for smooth rota-
steel bars under the straddle leg immediately in
tion.
back of the wheel housing to hold wheel at least 1
inch off of floor. 8. Reverse the above procedure to install new load
wheel.
4. Lower the lift truck onto the support.
9. Check wheel for free rotation.
R3973
7-4 901630
SECTION 8
ELEVATION SYSTEM SERVICING
8-1. GENERAL. 4. Lift the lift chains off the sheaves and lay the
The elevation system includes the mast, reach assem- chains on the mast support.
bly, lift chains, lift cylinder, ram head reach cylinders 5. Remove screws (23), washers (18), clamp bar
and tilt cylinders. (24) and wear spacers (13). Then lift the ram
head off the lift cylinder.
8-2. TELESCOPIC RAM HEAD REPLACEMENT 6. Remove snap rings (9), washers (10), sheaves
1. Lower the lift carriage fully. (11), and bearings (12) from ram head (14).
2. Disconnect the battery. 7. Reinstall ram head in reverse order of removal.
3. Slacken the lift chains by loosening the nut (3, 8. Adjust lift chains as described in paragraph 8-3.1.
Figure 8-1).
R3273
901630 8-1
R3275
8-2 901630
R3274
8-3. LIFT CHAINS. NOTE: On telescopic and full free lift trucks the
chains are adjusted on the rear of the reach
8-3.1. Lift Chain Length Adjustment assembly using jam nut (5, Figure 8-1 or 4,
Figure 8-2) and hex nut (4, Figure 8-1 or 21,
WARNING: Before attempting any adjustment make
Figure 8-2) on chain adjusting bolt (7, Figure
certain power is disconnected.
8-1 or 3, Figure 8-2). On trimast trucks the
The lift chains should be adjusted with the lift carriage chains are adjusted at the top of the mast
fully lowered. All slack must be removed from chains. using jam nut (3, Figure 8-3) and hex nut (4)
If there is slack in any chain, adjust the chain. Chains on chain adjusting bolt (7).
should be equally taut.
3. Loosen jam nut on lift chain adjusting bolt.
1. Fully lower lift carriage.
4. Take up slack in both lift chains by tightening the
2. Disconnect battery. hex nut on the chain adjusting bolt. Strive for
equal tension on chains.
901630 8-3
5. Align chain adjusting bolts so each they are paral- 4. Remove clevis pin (18) from chain adjusting bolt
lel to mast. (3).
CAUTION: At least 3 full threads must be present 5. Remove chain from sheave (14) and lay aside for
below hex nut after completion of adjust- repair.
ment. 6. Position new chain in place on sheave (14).
6. Tighten jam nuts securely while maintaining align- 7. Connect end of chain to adjusting bolt (3) with the
ment of adjusting bolts. clevis pin and retaining ring (18).
8-3.2. Lift Chain Replacement (Telescopic). 8-3.4. Lift Chain Replacement (Trimast).
1. Place a solid block on floor under the vertical 1. Place a solid block on floor under the vertical
members nearest the center of the reach assem- members nearest the center of the reach assem-
bly. bly.
2. Lower reach assembly until it is supported by the 2. Lower reach assembly until it is supported by the
block and the load chains are slack, then discon- block and the load chains are slack, then discon-
nect battery. nect battery.
WARNING: Before attempting any actual replace- WARNING: Before attempting any actual replace-
ment, make certain power is discon- ment, make certain power is discon-
nected. nected.
3. Remove the clevis pin (6, Figure 8-1) from end of 3. Remove the clevis pin (9, Figure 8-3) from end of
chain connected to mast cross brace. chain connected to reach assembly.
4. Remove clevis pin (6) from chain adjusting bolt 4. Remove clevis pin (9) from chain adjusting bolt
(7). (7).
5. Remove chain from sheave (11) and lay aside for 5. Remove chain from around sheaves (25) and lay
repair. aside for repair.
6. Position new chain in place on sheave (11). 6. Position new chain in place on upper sheave (25).
7. Connect end of chain to adjusting bolt (7) with the 7. Connect end of chain to the reach assembly with
clevis pin and retaining ring (6). the clevis pin and retaining ring (9).
8. Connect end of chain to mast cross brace with 8. Route the chain around the lower sheave (25)
clevis pin and retaining ring (6). and connect end of chain to adjusting bolt (7) with
clevis pin and retaining ring (6).
9. Adjust chain according to paragraph 8-3.1.
9. Adjust chain according to paragraph 8-3.1.
8-3.3. Lift Chain Replacement (Full Free Lift).
8-4. LIFT CYLINDER REMOVAL.
1. Place a solid block on floor under the vertical
members nearest the center of the reach assem- 8-4.1. Telescopic Models.
bly.
1. With the brake set and the lift truck wheels
2. Lower reach assembly until it is supported by the securely blocked, raise forks approximately three
block and the load chains are slack, then discon- feet from floor and position blocks or strong sup-
nect battery. ports under reach assembly back frame (4, Figure
WARNING: Before attempting any actual replace- 8-4).
ment, make certain power is discon- WARNING: Before disconnecting any hydraulic lines,
nected. make certain the system is not under
3. Remove the clevis pin (18, Figure 8-2) from end pressure. Refer to paragraph 9-1.
of chain connected to mast cross brace. 2. Disconnect the battery.
8-4 901630
R3254
901630 8-5
3. Remove the flow control valve as described in NOTE: Disassembly procedures are covered in SEC-
paragraph 9-7. TION 9.
4. Remove nipple, and street elbows from the bot- 11. Reinstall lift cylinder in reverse order of removal.
tom of the lift cylinder.
12. Adjust lift chains as described in paragraph 8-3.1.
5. Remove the ram head as described in paragraph
8-2. 8-4.3. Trimast
CAUTION: Hold lift cylinder securely during the final WARNING: Before disconnecting any hydraulic lines,
stages of this procedure. make certain the system is not under
pressure. Refer to paragraph 9-1.
6. Remove screw (17) and washer(s) (18 and 19)
from bottom of lift cylinder. 1. Fully lower the lift carriage.
7. Raise the lift cylinder up and out of the truck. 2. Disconnect the battery.
8. Place lift cylinder aside where further disassembly 3. Disconnect hose at the bottom of lift cylinder.
can be accomplished. Disassembly procedures
4. Using another lift truck or suitable jack, raise lift
are covered in section 9.
carriage far enough to remove chains from
9. Reinstall lift cylinder in reverse order of removal. around sheaves. Lay chains aside and lower lift
10. Adjust chain according to paragraph 8-3.1. carriage.
5. Remove lock nut (28, Figure 8-3) and roll pin (16)
8-4.2. Full Free Lift that secures top of lift cylinder to the inner-most
WARNING: Before disconnecting any hydraulic lines, mast.
make certain the system is not under 6. Remove snap ring (17) that secures the bottom of
pressure. Refer to paragraph 9-1. lift cylinder to the inner mast.
1. Fully lower the lift carriage. WARNING: Lift cylinder must be supported during
2. Disconnect the battery. the next step.
3. Disconnect hose at the bottom of lift cylinder. 7. Support lift cylinder and using another lift truck or
4. Using another lift truck or suitable jack, raise lift suitable jack, raise inner-most mast far enough to
carriage far enough to remove chains from clear top of lift cylinder.
around sheaves. Lay chains aside and lower lift 8. Lift cylinder up and out of truck.
carriage. 9. Place lift cylinder aside where further disassembly
5. Remove lock nut (9, Figure 8-2) and roll pin (8) can be accomplished.
that secures top of lift cylinder to the inner mast. 10. Remove grease fittings (18), snap rings (19),
6. Remove the hex head cap screw, (7) lock washer washers (21), sheaves (25), and bearings (24)
(19) and flat washer (6) securing the bottom of lift from cylinder (38).
cylinder.
NOTE: Disassembly procedures are covered in SEC-
WARNING: Lift cylinder must be supported during TION 9.
the next step.
11. Reinstall lift cylinder in reverse order of removal.
7. Support lift cylinder and using another lift truck or 12. Adjust lift chains as described in paragraph 8-3.1.
suitable jack, raise inner mast far enough to clear
top of lift cylinder. 8-5. REACH CYLINDER REMOVAL.
8. Lift cylinder up and out of truck.
WARNING: Before disconnecting any hydraulic lines,
9. Place lift cylinder aside where further disassembly make certain the system is not under
can be accomplished. pressure. Refer to paragraph 9-1.
10. Remove grease fittings (16), snap rings (15),
washers (12), sheaves (14), and bearings (13) 1. Lower the forks as far as possible.
from cylinder (23). 2. Disconnect the battery.
8-6 901630
R3253
901630 8-7
6. Install rollers (21) on new carriage (19) and 9. Remove snap ring (12) and thrust washer (13)
secure with nuts (20). securing pivot shaft (10).
7. Position new carriage (19) on front frame (16) and WARNING: Support struts (9 and 15) before per-
install shaft (17) being careful to align the pin hole forming steps 10. and 11. to prevent
in the shaft with the pin hole in carriage (19). struts from falling.
8. Install pin (18).
10. Install a bolt in the end of pivot shaft (10) and pull
9. Reinstall forks. the shaft out of the struts. Remove outer strut (9).
8-7.2. Fork Frame Replacement. 11. Remove two nuts (3) and two bolts (14) that
secure the inner strut (15) to the top of back frame
1. Remove the carriage (19, Figure 8-4) as
(4) and remove inner strut (15).
described in paragraph 8-7.1.
12. Remove snap ring (12), thrust rings (13), and
2. Remove both tilt cylinders as described in para-
roller (22) from the strut.
graph 8-6.
13. Repeat step 12. for the remaining rollers.
3. Free tilt cylinder hoses (13 and 21, Figure 8-5)
from fork frame (16, Figure 8-4). 14. Reinstall struts in reverse order of disassembly.
WARNING: Support fork frame (16) before perform- 8-7.4. Back Frame and Mast Replacement.
ing step 4. to prevent frame from falling. 1. Remove the carriage (19, Figure 8-4) as
4. Remove two nuts (3) and two bolts (14) that described in paragraph 8-7.1.
secure the fork frame (16) to the top of outer strut 2. Remove both tilt cylinders as described in para-
(9) and remove fork frame (16). graph 8-6.
5. Reinstall fork frame (16) in reverse order of disas- 3. Remove front frame as described in paragraph 8-
sembly. 7.2.
4. Remove struts as described in paragraph 8-7.3.
8-7.3. Strut Replacement.
5. Tag and disconnect all tilt and reach hoses at the
1. Remove the carriage (19, Figure 8-4) as
manifolds located on the back of the back frame
described in paragraph 8-7.1.
(4).
2. Remove both tilt cylinders as described in para-
6. Remove the manifolds from the back frame (4).
graph 8-6.
7. Disconnect lift chains from back frame (4) and lay
3. Tag and remove tilt cylinder hoses (13 and 21,
chains clear of lift back frame.
Figure 8-5) from manifolds (23).
8. Use a chain hoist to pull back frame free from
4. Tag and disconnect remaining tilt cylinders hoses
mast.
(12 and 13) at manifolds (23).
9. Remove lift cylinder as described in paragraphs 8-
5. Remove screws (22), lockwashers (10) and mani-
4.
folds (23) from strut (15, Figure 8-4).
10. After removing lift cylinder, use a chain hoist to
6. Remove both reach cylinders as described in
remove the inner-mast from the chassis frame.
paragraph 8-5.
7. Free the tilt cylinder hoses and the reach cylinder CAUTION: Do not lean against wall or where it may
hoses from the struts. accidently fall or be hit.
8. Remove fork frame (16) as described in para- 11. Installation of a new or repaired mast is performed
graph 8-7.2. in the reverse order of removal. Lubricate the
newly installed mast by following the instructions
in paragraph 8-8.
8-8 901630
8-8. LUBRICATION OF MAST.
1. Fully lower the lift carriage.
2. Apply a Lithium base general purpose grease,
using a lubrication gun, to the grease fittings of
the following components:
a. Outer-mast rollers
b. Chain sheaves
c. Inner-mast rollers
d. Lift carriage rollers-telescopic and non-tele-
scopic (six places)
e. Lift carriage rollers-TRIMAST and Full Free
Lift (four places)
3. Apply a Lithium base general purpose grease with
a brush to the full length of masts where rollers
touch.
901630 8-9
NOTES
8-10 901630
SECTION 9
HYDRAULIC SYSTEM SERVICING
WARNING: Hydraulic system pressure must be 7. Operate the hydraulic controls and check for
relieved before removing hydraulic sys- leaks.
tem components. Use the following pro-
cedure to relieve system pressure: 9-3. FILTER REPLACEMENT.
1. Fully lower the lift carriage unless the procedure 9-3.1. Sump Filter.
for a component directs differently.
NOTE: Figure 9-1 through Figure 9-4 show the loca-
2. Disconnect battery. tion of the sump filter. The procedure for
replacement is the same on all models.
CAUTION: Use rags and a suitable container to
catch any dripping oil when the hydraulic WARNING: Before disconnecting any hydraulic lines,
lines are disconnected. Wipe off any make certain the system is not under
spilled oil immediately. pressure. Refer to paragraph 9-1.
3. Obtain a suitable container to catch any oil that 1. Remove reservoir drain plug (31, Figure 9-1) and
may escape when opening a line. drain hydraulic oil.
4. Open the low pressure line at any convenient 2. Remove the control knobs from the control levers.
connection near the component that is to be
3. Remove the hydraulic compartment access cover.
repaired or replaced.
4. Loosen hose clamp (18) and remove hose (17)
9-2. LINE, FITTING and HOSE REPLACEMENT. from nipple (26).
5. Remove nuts (27), and lift off hold-down plate
NOTE: Leaking hydraulic fittings can sometimes be
(28).
remedied by simply tightening the fitting. If
this does not remedy the leak, the fitting or 6. Remove sump filter (29) from reservoir (1), being
line must be replaced. A leak in the suction careful to retain O-ring (30). Check O-ring for
line between the pump and the reservoir will damage.
sometimes cause hydraulic oil to foam 7. Install new filter, and reconnect parts discon-
through the vent. nected in steps 4. through 6.
WARNING: Before disconnecting any hydraulic lines, 8. Clean the drain plug thoroughly.
make certain the system is not under 9. Reinstall the drain plug.
pressure. Refer to paragraph 9-1.
NOTE: Refill only with Big Joe hydraulic oil, and only
1. Remove the reservoir drain plug and drain the while the platform is completely lowered.
hydraulic oil into a suitable container. Refill until oil is to the “FULL” mark on the dip
2. Remove the leaking line or fitting and replace it stick. Refer to SECTION 3 for oil capacities.
with a new one. 10. Remove the reservoir vent cap, fill the reservoir to
3. Clean the drain plug thoroughly. the “FULL” mark on the dip stick, and replace the
4. Reinstall the drain plug. vent cap.
11. Reconnect battery.
NOTE: Refill only with Big Joe hydraulic oil, and only
while the platform is completely lowered. 12. Operate the hydraulic controls and check for
Refill until oil is to the “FULL” mark on the dip leaks.
stick. Refer to SECTION 3 for oil capacities. 13. Install the hydraulic compartment access cover.
5. Remove the reservoir vent cap, fill the reservoir to 14. Install the control knobs on the control levers.
the “FULL” mark on the dip stick, and replace the
vent cap.
901630 9-1
R3245
Figure 9-1 Reservoir, Pump and Control Valve Hoses (PDR 20 Telescopic)
9-2 901630
R3246
Figure 9-2 Reservoir, Pump and Control Valve Hoses (PDR 30 Telescopic)
901630 9-3
R3247
Figure 9-3 Reservoir, Pump and Control Valve Hoses (PDR 20 Trimast and Full Free Lift)
9-4 901630
R3248
Figure 9-4 Reservoir, Pump and Control Valve Hoses (PDR 30 Trimast and Full Free Lift)
901630 9-5
9-3.2. In-Line Filter. 9. Clean the drain plug thoroughly.
WARNING: Before disconnecting any hydraulic lines, 10. Reinstall the drain plug.
make certain the system is not under NOTE: Refill only with Big Joe hydraulic oil, and only
pressure. Refer to paragraph 9-1. while the platform is completely lowered.
1. Remove the reservoir drain plug and drain the Refill until oil is to the “FULL” mark on the dip
hydraulic oil into a suitable container. stick. Refer to SECTION 3 for oil capacities.
2. Disconnect hose (13, Figure 9-3, or 18, Figure 9- 11. Remove the reservoir vent cap, fill the reservoir to
4) at the in-line filter and remove elbow (11, Fig- the “FULL” mark on the dip stick, and replace the
ure 9-3) or nipple (17, Figure 9-4). vent cap.
3. Remove in-line filter (14, Figure 9-3 or 5, Figure 9- 12. Reconnect battery.
4). 13. Operate the hydraulic controls and check for
4. Remove end plug (Figure 9-5) of filter body. leaks.
5. Remove sintered bronze filter element (Figure 9-
5) from filter body and clean or discard. 9-4. HYDRAULIC PUMP AND MOTOR ASSEMBLY
6. Check that spring (Figure 9-5) is in place in filter WARNING: Before disconnecting any hydraulic lines,
body then install the filter element in the filter body make certain the system is not under
and attach end plug of filter body. pressure. Refer to paragraph 9-1.
9-6 901630
R295, R429
NOTE: Refill only with Big Joe hydraulic oil, and only Repair parts for the solid-spool control valve are illus-
while the platform is completely lowered. trated in Figure 9-7. Information is provided for install-
Refill until oil is to the “FULL” mark on the dip ing seals (o-rings) on the control valve spools in
stick. Refer to SECTION 3 for oil capacities. paragraph 9-5.2. Procedures for testing the micro-
switch prior to installing the valve in a truck are given
11. Remove the reservoir vent cap, fill the reservoir to in paragraph 9-5.3.
the “FULL” mark on the dip stick, and replace the
vent cap. 9-5.1. Control Valve Replacement
12. Reconnect battery. WARNING: Before disconnecting any hydraulic lines,
13. Operate the hydraulic controls and check for make certain the system is not under
leaks. pressure. Refer to paragraph 9-1.
901630 9-7
SEAL KIT FOR ALL SPOOLS
PART NO. 900368-03
4. Remove cotter pins (9) and clevis pins (8) secur- 13. Reconnect battery.
ing the control levers to the valve spools. 14. Operate the hydraulic controls and check for
5. Tag, disconnect and plug the wires and hoses leaks.
from the control valve. 15. Install the hydraulic compartment access cover.
6. Remove the control valve by removing the three 16. Install the control knobs on the control levers.
screws (15) that secure the valve to the mount.
9-5.2. Seal Replacement
7. Install a rebuilt or new valve and secure with three
screws (15). The seals (o-rings) are provided in a seal kit, part num-
ber 900368. This kit is common to several series of Big
8. Connect the wires and hoses to the control valve.
Joe trucks. Refer to Figure 12-18 for identification of o-
9. Secure the control levers to the valve spools with rings supplied in the kit.
clevis pins (8) and cotter pins (9).
The seals (o-rings) on the control valve spool may
10. Clean the drain plug thoroughly. require periodic replacement to prevent leakage from
11. Reinstall the drain plug. the control valve. Use the following procedure for
replacing the seals.
NOTE: Refill only with Big Joe hydraulic oil, and only
while the platform is completely lowered. 1. Remove control valve from truck in accordance
Refill until oil is to the “FULL” mark on the dip with procedure in paragraph 9-5.1.
stick. Refer to SECTION 3 for oil capacities. 2. Remove screws (30, Figure 9-7) and remove
motor switch bracket and end cap assembly.
9-8 901630
3. Slide the spool out toward the top of the valve 9-5.3. Control Valve Microswitch Adjustment
only far enough to expose the top o-ring as shown
The control valve microswitches should be adjusted to
in Figure 9-8.
insure proper opening and closing prior to mounting
the control valve in the truck. Use the following proce-
dure to perform adjustment:
1. Attach a continuity tester to the microswitch con-
tacts at the points indicated in Figure 9-9.
R786
901630 9-9
9-6. STACK CONTROL VALVE SERVICE 9. Secure the control levers to the valve spools with
clevis pins (20) and cotter pins (19).
9-6.1. Control Valve Replacement
10. Clean the drain plug thoroughly.
WARNING: Before disconnecting any hydraulic lines, 11. Reinstall the drain plug.
make certain the system is not under
pressure. Refer to paragraph 9-1. NOTE: Refill only with Big Joe hydraulic oil, and only
while the platform is completely lowered.
1. Remove the reservoir drain plug and drain the Refill until oil is to the “FULL” mark on the dip
hydraulic oil into a suitable container. stick. Refer to SECTION 3 for oil capacities.
2. Remove the control knobs (12, Figure 9-10) from
12. Remove the reservoir vent cap, fill the reservoir to
control levers (9, 10 and 11).
the “FULL” mark on the dip stick, and replace the
3. Remove the hydraulic compartment access cover. vent cap.
4. Remove cotter pins (19) and clevis pins (20) 13. Reconnect battery.
securing the control levers to the valve spools.
14. Operate the hydraulic controls and check for
5. Tag, disconnect and plug the wires and hoses leaks.
from the control valve.
15. Install the hydraulic compartment access cover.
6. Remove the control valve by removing the five
16. Install the control knobs on the control levers.
screws (7) and five washers (8) that secure the
valve to the mount. 9-6.2. Control Valve Repair
7. Install a rebuilt or new valve and secure with the
Refer to Figure 12-20 for repair parts of the spool
five screws (7) and five washers (8).
valve.
8. Connect the wires and hoses to the control valve.
12 7 13
8
14
15
16
11 17
3
4
10
5
9
8
7
6
19
20
21
R5980
1
9-10 901630
NOTES
901630 9-11
9-7. LIFT FLOW CONTROL VALVE REPLACEMENT 5. On 24-volt units, remove reducers (19) from flow
(Telescopic Only) control valve (20) and install them in the new flow
control valve.
1. Raise the forks high enough to gain access to the
flow control valve (20, Figure 9-11). 6. Install new flow control valve making certain direc-
2. Place a strong support under the inner mast and tion of free flow (as marked on valve) is toward lift
lower forks so that inner mast rests on the sup- cylinder.
port. 7. Install fitting (18) and reconnect hose (11).
8. Reconnect battery.
WARNING: Before disconnecting any hydraulic lines,
make certain the system is not under 9. Raise forks, then remove support.
pressure. Refer to paragraph 9-1. 10. Fully lower the lift carriage and check the hydrau-
lic oil level.
3. Disconnect hose assembly (11) and fitting (18).
11. Raise and lower the lift carriage and check for
4. Remove flow control valve (20).
leaks.
9-12 901630
R3249
Figure 9-11 Control Valve to Lift Cylinder and Reach Cylinder (PDR 20 and 30 Telescopic)
901630 9-13
9-8. LIFT CYLINDER REPAIR Cylinders equipped with piston (14), pull off
piston (14) and O-ring (7). Remove seal (15) from
9-8.1. Telescopic Trucks
piston (14).
NOTE: Removal procedures are covered in SEC-
NOTE: Cylinders equipped with piston (8), install ret-
TION 8.
rofit kit 907120.
CAUTION: Use proper pipe clamp-type vise. The
cylinder will be distorted if the vise is NOTE: Cylinders equipped with piston (14), install
tightened too much. packing kit 907119.
6. Coat seal (15) and piston (14) liberally with petro-
1. Secure lift cylinder tube assembly in vise and
leum jelly. Install new seal (15) on piston (14).
remove gland nut (3, Figure 9-12), then wiper ring
(2), and top O-ring (4). 7. Install new O-ring (7), piston (14) and nut (11)
2. Pull out cylinder ram rod (5). onto cylinder ram (5).
8. Remove cylinder ram (5) from vise.
3. Remove lift cylinder tube assembly from vise.
CAUTION: To prevent cylinder damage, use proper
CAUTION: Use proper pipe clamp-type vise with
pipe clamp vise. The cylinder will be dis-
non-marring jaws to prevent damaging
torted if the vise is tightened too much.
the finish on the ram.
4. Secure cylinder ram rod (5) in vise. 9. Secure lift cylinder tube (1) in vise.
10. Install cylinder ram (5) into cylinder tube (1).
5. Remove nut (11).
11. Install new O-ring (4) and wiper ring (2) on gland
Cylinders equipped with piston (8), pull off bot-
nut (3).
tom washer (10), packing assembly (9), piston
(8), and bottom O-ring (7). 12. Install gland nut (3) in cylinder tube (1).
13. Remove lift cylinder assembly from vise.
USED ON TRUCKS
SERIAL NUMBERS
333423 TO 351487
ORDER RETROFIT
KIT 907120
R6107
14 1 15 1
15 1
Figure 9-12. Lift Cylinder - Telescopic
9-14 901630
9-8.2. Trimast and Full Free Lift Trucks 2. Unthread gland nut (4) from outside tube (1).
FFL Serial Number 333423 TO 335391 3. Remove primary rod (2) by sliding out of outside
158 In Trimast Serial Number 333423 TO 335477 tube (1).
194 In Trimast Serial Number 333423 TO 335350
4. Remove gland nut (5) by unthreading from pri-
NOTE: Removal procedures are covered in SEC- mary rod (2).
TION 8. Refer to Table 9-1 and Table 9-2 for 5. Secondary rod (3) can now be removed by sliding
proper packing kit. it out of the primary rod (2).
Refer to Figure 9-13 and proceed as follows. 6. Remove base (7) by unthreading it from the pri-
mary rod (2).
CAUTION: Use proper clamp-type vise. The cylinder
will be distorted if the vise is tightened 7. Remove flow regulator (6) and o-ring.
too much. Assemble lift cylinder by reversing the disassembly
procedure. For ease of assembly when assembling
1. Secure lift cylinder tube assembly in vise.
threaded parts, apply a coating of white lead replace-
CAUTION: Use proper spanner wrench when ment to the threads.
removing gland nut to prevent damage
to cylinder.
R3631A
901630 9-15
Table 9-1 Trimast Lift Cylinders
9-8.3. Trimast and Full Free Lift Trucks 2. Unthread bearing housing (9) from outside tube
FFL Serial Number 335392 AND HIGHER (1).
158 In Trimast Serial Number 335478 TO 342111 3. Remove primary rod (2) by sliding out of outside
194 In Trimast Serial Number 335351 AND HIGHER tube.
NOTE: Removal procedures are covered in Section 4. Remove gland nut (5) by unthreading from pri-
8. Refer to Table 9-1 and Table 9-2 for proper mary rod.
packing kit. 5. Secondary rod (3) can now be removed by sliding
Refer to Figure 9-14 and proceed as follows. it out of the bottom of the primary rod.
6. Remove base (7) by unthreading it from the sec-
CAUTION: Use proper clamp-type vise. The lift cyl- ondary rod.
inder will be distorted if the vise is tight-
ened too much. 7. Remove flow regulator (6) and o-ring.
Assemble lift cylinder by reversing the disassembly
1. Secure lift cylinder tube assembly in vise.
procedure. Be sure to use the proper seal kit. For
CAUTION: Use proper spanner wrench when ease of assembly when assembling threaded parts,
removing bearing housing (9) to prevent apply a coating of white lead replacement to threads.
damage to cylinder.
9-16 901630
USED ON 158 INCH TRUCKS SERIAL
NUMBERS 335478 TO 342111
R4335
901630 9-17
9-8.4. Trimast Lift Trucks CAUTION: Use proper clamp-type vise. The lift cyl-
158 In Trimast Serial Number 342112 AND HIGHER inder will be distorted if the vise is tight-
ened too much.
NOTE: Removal procedures are covered in SEC-
TION 8. Refer to Table 9-1 and Table 9-2 for 1. Secure lift cylinder tube assembly in vise and
proper packing kit. untread gland nut (4) from outer cylinder.
After determining model and ordering correct packing 2. Remove primary rod (2) by sliding out of outside
kit, you will need three spanner wrenches to remove tube (1).
gland nuts. 3. Remove the gland nut (5) from primary rod (2) by
McMaster Carr #5472A1 unthreading.
pin diameter 1/8” overall 4. Slide gland nut (4) from primary rod (2).
length 6-3/8 5. Secondary rod (3) can now be removed by sliding
McMaster Carr #5481A1 it out of primary rod (2).
pin diameter 3/16” overall 6. Remove base (7) by unthreading it from second-
length 6-3/8 ary rod (3).
McMaster Carr #5481A2 7. Remove snap ring. Flow regulator (6) and O-ring
pin diameter 1/4” overall can now be removed.
length 8-1/4
8. Assembly lift cylinder by reversing the disassem-
CAUTION: Do not attempt to remove gland nuts with bly procedure. For ease of assembly when
a hammer and punch. Gland nuts are a assembling threaded parts, apply a coating of
soft metal. white lead replacement to the threads.
Refer to Figure 9-15 and proceed as follows.
R1898
9-18 901630
9-9. REACH CYLINDER REPAIR 4. Secure piston rod in vise.
9-9.1. Reach Cylinder (Truck Serial Numbers 5. Remove nut (2), piston (5) and O-ring (6) from
333423 TO 338311) piston rod (8).
6. Remove gland nut (11) from piston rod (8).
NOTE: Removal procedures are covered in SEC-
7. Remove grease fittings from cylinder tube (1) and
TION 8.
piston rod (8).
WARNING: To prevent cylinder damage, use proper
NOTE: Before reassembling the hydraulic cylinder, it
pipe clamp vise. The cylinder will be dis-
is recommended that back-up rings (3), O-
torted if the vise is tightened too much.
ring (4), O-ring (6), O-ring (7), back-up ring
1. Secure the cylinder assembly in a vise and (12), O-ring (4), and rod wiper (10) be
remove internal retaining ring (9, Figure 9-16). replaced.
2. Pull out piston rod (8). 8. Reassemble the cylinder in reverse order of dis-
3. Remove the cylinder tube (1) from the vise. assembly.
PACKING KIT
901312 CONTAINS:
ITEM QTY
3 3
4 2
6 1
7 1
9 1
10 1
12 1
R3976
901630 9-19
9-9.2. Reach Cylinder (Truck Serial Numbers 4. Secure piston rod (8) in vise.
338312 AND HIGHER) 5. Remove nut (2) and piston (5) from piston rod (8).
NOTE: Removal procedures are covered in SEC- 6. Remove top piston (11) from piston rod (8).
TION 8. 7. Remove grease fittings (13) from barrel (1) and
WARNING: To prevent cylinder damage, use proper piston rod (8).
pipe clamp vise. The cylinder will be dis- NOTE: Before reassembling the hydraulic cylinder, it
torted if the vise is tightened too much. is recommended that back-up rings (3), O-
1. Secure the cylinder assembly in a vise. Work ring (4), O-ring (6), O-ring (7), back-up ring
internal retaining ring (9, Figure 9-17) out the hole (12), O-ring (4), and rod wiper (10) be
in barrel (1). replaced.
2. Pull out piston rod (8). 8. Reassemble the cylinder in reverse order of dis-
3. Remove the barrel (1) from the vise. assembly.
PACKING KIT
901431 CONTAINS:
ITEM QTY
3 3
4 2
6 1
7 1
10 1
12 1
R4343
9-20 901630
9-10.TILT CYLINDER REPAIR WARNING: To prevent damaging the finish on rod
(6), use proper pipe clamp vise with non-
9-10.1.Tilt Cylinder (Truck Serial Numbers 333423 marring jaws.
TO 338311)
4. Secure piston rod in vise.
NOTE: Removal procedures are covered in SEC-
5. Remove nut (2), piston (5) and guide (10) from
TION 8.
piston rod (6).
WARNING: To prevent cylinder damage, use proper
NOTE: Before reassembling the hydraulic cylinder, it
pipe clamp vise. The cylinder will be dis-
is recommended that back-up rings (3), O-
torted if the vise is tightened too much.
ring (4), O-ring (12), back-up ring (11), O-ring
1. Secure the cylinder assembly in a vise and (4), and rod wiper (7) be replaced.
remove external retaining ring (8, Figure 9-18)
and internal retaining ring (9). 6. Reassemble the cylinder in reverse order of dis-
assembly.
2. Pull out piston rod (6).
3. Remove the cylinder tube (1) from the vise.
PACKING KIT
901313 CONTAINS:
ITEM QTY
3 3
4 2
7 1
8 1
9 1
11 1
12 1
R3975
901630 9-21
9-10.2.Tilt Cylinder (Truck Serial Numbers 338312 WARNING: To prevent damaging the finish on rod
AND HIGHER) (7), use proper pipe clamp vise with non-
marring jaws.
NOTE: Removal procedures are covered in SEC-
TION 8. 4. Secure piston rod (7) in vise.
WARNING: To prevent cylinder damage, use proper 5. Remove nut (2), piston (5) and top piston (10)
pipe clamp vise. The cylinder will be dis- from piston rod (6).
torted if the vise is tightened too much. NOTE: Before reassembling the hydraulic cylinder, it
1. Secure the cylinder assembly in a vise. Work is recommended that back-up rings (3), O-
internal retaining ring (9, Figure 9-19) out the hole rings (4), O-ring (6), O-ring (12), back-up ring
in barrel (1). (11), and rod wiper (8) be replaced.
2. Pull out piston rod (7). 6. Reassemble the cylinder in reverse order of dis-
3. Remove the barrel (1) from the vise. assembly.
PACKING KIT
901424 CONTAINS:
ITEM QTY
3 3
4 2
6 1
8 1
11 1
12 1
R4344
9-22 901630
SECTION 10
ELECTRICAL COMPONENTS
R1865
Figure 10-1 Single Pole Contactor, 2nd Speed, 3rd Speed Dynamic Brake
901356 10-1
1. Remove spring stud (7) and spring (6). 8. Place moving contact assembly (8) on armature
2. Remove nut holding armature plate retainer (5) plate then attach braid assembly (3) to contact
and remove retainer by squeezing in on tabs and stud.
lifting up. 9. Place retainer (5) over contact stud and slip the
3. Slide braid assembly (3) off contact (8) and two tabs on retainer (5) into the two slots in arma-
remove contact (8) and armature plate (9) and ture plate (9). Secure with hex nut.
spring (6). 10. Secure moving contact (8) to armature (9) with
4. Use a 10 mm wrench to remove nut and flat spring (6) and spring stud (7).
washer holding front contact (12) and remove
10-2.3.Forward-Reverse Double Pole Contactor
contact.
Disassembly. (Refer to Figure 10-2)
NOTE: If only contacts are to be replaced, no further
NOTE: Order contactor tip kit part number 900531-
disassembly is required. Proceed to step 5 to
09. One kit repairs one contactor. Kit includes
replace coil.
items (3, 5, 8, 12 and 16).
5. Remove spacer (13).
1. Remove spring (7) and spring (6).
6. Squeeze sides of front molding (4) and pull for-
2. Remove nut bolt and washer securing bus bar
ward to disengage from base molding (1).
(14), (if used) to back contact (16).
Remove base molding and remove front molding
from frame (2). 3. Slide back contact (16) up as far as possible then
squeeze sides of rear molding (17) together and
7. Coil can now be removed from frame (2) by lift off frame (2). Separate two sides of rear mold-
removing 3/4 inch long hex head screw and flat ing and remove back contact (16).
washer.
4. Remove nut holding armature plate retainer (5)
10-2.2.2nd Speed, 3rd Speed, Dynamic Brake Sin- and remove retainer by squeezing in on tabs and
gle Pole Contactor Reassembly. (Refer to Figure lifting up.
10-1) 5. Slide braid assembly (3) off contact (8) and
1. Place 1-1/4 inch long hex head bolt through bot- remove contact (8) and armature plate (9) and
tom of front molding (4) and slide molding onto spring (6).
frame (2). 6. Use a 10 mm wrench to remove nut holding front
2. Attach coil (11) to frame (2) with flatwasher and 5/ contact (12) and remove contact.
8 inch long hex head bolt. Be sure braid assembly
NOTE: If only contacts are to be replaced, no further
(3) has been attached to frame (2) with 3/4 inch
disassembly is required. Proceed to step 7 to
bolt, flat washer, lock washer and nut. Use 10mm
replace coil.
wrench on nut.
3. Attach frame (2) to base molding (1) by engaging 7. Remove spacer (13).
slots at bottom of frame (2) behind flanges near 8. Squeeze sides of front molding (4) and pull for-
lower edge of base molding (1). ward to disengage from base molding (1).
4. Snap slots of top of front molding (4) into flanges Remove base molding and remove front molding
of base (1). Coil assembly should now securely from frame (2).
attach to base (1). 9. Coil can now be removed from frame (2) by
5. Install spacer (13) in front molding (4) and install removing 3/4 inch long hex head screw and flat
front contact (12) secure with washer, lock washer washer.
and hex nut. Use 10 mm wrench on nut.
10-2.4.Forward-Reverse Double Pole Contactor
6. Place contactor on work surface with base mold- Reassembly. (Refer to Figure 10-2)
ing down. Place spring (6) on center of pole piece
(10). 1. Place 1-1/4 inch long hex head bolt through bot-
tom of front molding (4) and slide molding onto
7. Position armature plate (9) against frame (2).
frame (2).
10-2 901356
2. Attach coil (11) to frame (2) with flat washer and 5/ 8. Place moving contact assembly (8) on armature
8 inch long hex head bolt. Be sure braid assembly plate then attach braid assembly (3) to contact
(3) has been attached to frame (2) with 3/4 inch stud.
bolt, lock washer, flat washer and nut. Use 10 mm 9. Place retainer (5) on contact stud and slip the two
wrench on nut. tabs on retainer (5) into the two slots in armature
3. Attach frame (2) to base molding (1) by engaging plate (9). Secure with hex nut.
slots of bottom of frame (2) behind flanges near 10. Place two parts of back molding (17) together and
lower edge of base molding (1). slide contact (16) into slot in molding.
4. Snap slots at top of front molding (4) into flanges 11. Squeeze back molding together and place
of base (1). Coil assembly should now be grooves in back molding on frame (2). Push mold-
securely attached to base (1). ing all the way down.
5. Install spacer (13) in front molding (4) and install 12. Release back molding and press back contact
front contact (12) secure with washer, lock washer (16) down into position. Armature will need to be
and hex nut. Use a 10 mm wrench on nut. pressed down to position back contact.
6. Place contactor on work surface with base mold- 13. Reattach bus bar (14) (if used) to back contact
ing down. Place spring (6) on center of pole piece (16) using hex nut and washers.
(10).
14. Secure moving contact (8) to armature (9) with
7. Position armature plate (9) against frame (2). spring (6) and spring stud (7).
R1866
901356 10-3
10-3.PUMP MOTORS. 2. Disconnect the battery quick disconnect (33, fig-
ure 10-3).
Three different pump motor assemblies have been
used on the PDR truck. Refer to the following chart to 3. Lift the battery out of the battery compartment.
determine the proper pump motor. 4. Lower the new battery in the battery compart-
ment.
VOLTS PUMP SERIAL NO.
DC MOTOR EFFECTIVITY 5. Reconnect the battery quick disconnect (33).
PARTS NO.
12 900960 333423 TO 334371 10-6.HIGH SPEED LIMIT SWITCH.
12 901300 334372 AND HIGHER 1. Remove the two screws (30, Figure 10-3), two
24 905053 333423 AND HIGHER lockwashers (18), and two washers (5) securing
switch mounting bracket (27) to frame.
NOTE: Removal procedures are covered in SEC- 2. Remove high speed limit switch (28) from bracket,
TION 8. and then disconnect wiring from the switch.
Refer to applicable Figure 12-48, Figure 12-49 and 3. Connect the wiring to the new switch and install
Figure 12-50 for motor disassembly. the switch onto the bracket.
10-4 901356
1. SEE SUPPLEMENT 187 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 333423 TO 334630
2. SEE SUPPLEMENT 220 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 334631 AND
HIGHER
R3262
901356 10-5
NOTES
10-6 901356
SECTION 11
OPTIONAL EQUIPMENT
901356 11-1
NOTES
11-2 901356
SECTION 12
ILLUSTRATED PARTS BREAKDOWN
Following is an illustrated parts breakdown of assemblies and parts associated with the PDR Lift Truck.
901630 12-1
1. SEE SUPPLEMENT 207 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL SEE FIGURE 12-2
NUMBER 333423 TO 334630 FOR SWITCHES
R3837
12-2 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505050-01 CONTROL HEAD 1 20 072400-01 . HEX HD. SLOTTED SCREW, 4
(STANDARD) 6-32 X 1/2
— 505050-02 CONTROL HEAD 1 21 072415 . PAN HD. SCREW, THREAD 1
(LIFT IN HANDLE) CUTTING
— 505050-03 CONTROL HEAD 1 22 073461 . SOCKET SET SCREW 2
(LIFT/LOWER IN HANDLE) 23 074711 . SPACER 1
1 005647 . CONNECTOR 1 24 075088 . RETURN SPRING 1
2 018202 . SWITCH INSULATOR 1 25 075510 . COMPRESSION SPRING 2
3 020669 . MICRO SWITCH 1 26 077007 . WASHER, FLAT 4
4 020775 . MICRO SWITCH 4 27 077204 . SPLIT LOCK WASHER #6 4
5 052956 . FLANGED BEARING 2 28 402827 . SHAFT 1
6 056617 . FORWARD-REVERSE DECAL 1 29 402828 . CAP 2
7 059633 . HEX LOCKNUT, 2-56 2 30 402830 . BOTTOM ACCESS COVER 1
8 059634 . HEX LOCKNUT, 4-40 2 31 404421 . GRIP-RUBBER CLAD 2
9 060579 . DOWEL PIN, 1/4 X 15/16 2 (STANDARD)
10 060942 . ROLL PIN, 1/8 X 1-1/4 2 31 403358 . GRIP-ALUM 2
(OPTIONAL)
11 061016 . ROLL PIN, 1/4 X 3 2
32 402836 . SPACER 2
12 061200-01 . SPIRAL PIN, 3/16 X 1 1
33 402837 . BRACKET 1
13 067416 . PAN HD. SCREW, 6-32 X 1/2 4
34 402839 . TUBE 2
14 068189 . RD. HD. SCREW, 4-40 X 1-7/8 2
35 402840 . CAM 1
15 069462 . SLOTTED FLAT HD. SCREW, 2
6-32 X 3/4 36 402841 . HANDLE GUARD 1
16 069463 . SLOTTED FLAT HD. SCREW, 2 37 402843 . PAD 2
6-32 X 1 38 504538-01 . SWITCH WIRE ASSEMBLY 3
17 069478 . PHILLIPS FLAT HD. SCREW, 4 39 505052 . SWITCH BRACKET 1
1/4-20 X 3/4 40 800272 . CONTROL LEVER 2
18 069715 . SOCKET FLAT HD. SCREW, 2 41 800273 . CONTROL HANDLE 1
1/4-20 X 3/4
42 800274 . COVER 1
19 070486 . ROUND HD. SLOTTED 2
MACHINE SCREW .
901630 12-3
1. SEE SUPPLEMENT 207 FOR TRANSISTOR 2. SEE SUPPLEMENT 220 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL SPEED CONTROL TRUCKS SERIAL
NUMBER 333423 TO 334630 NUMBER 334631 AND HIGHER
R341
AR - AS REQUIRED
12-4 901630
R3966
901630 12-5
HANDLE RETURN SPRING
KIT 901325 CONTAINS:
ITEM QTY
4 1
5 1
6 1
7 1
14 1
15 1
25
22
17
R5994 R5384
12-6 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505765-01 CONTROL ARM ASSEMBLY 1 13 800275 . STEERING ARM 1
1 065569 . SOCKET HEAD SCREW, 1 14 285302 * . SPRING PIN, 1/4 1
7/16-14 X 2-1/4 15 285303 * . SPRING PIN, 3/8 1
2 401127 . SPACER 1 16 800204 . TUBE CLAMP 1
3 504364 . CLAMP ASSY 1 17 800206 ** . PIVOT CAP 1
4 501371 * . SPRING TUBE ASSY 1 17 402363 *** . PIVOT CAP 1
5 075060 * . STEERING ARM RETURN 1 18 052925 . . . FLANGED BEARING 1
SPRING 19 052922 . . . FLANGED BEARING 1
6 059426 * . HEX NUT, 5/16-18 2 20 501673 . BRAKE ROD 1
7 077210 * . LOCK WASHER, 5/16 2 21 069478 . PHILLIPS FLAT HD. SCREW, 2
8 060417 . COTTER PIN, 3/32 X 3/4 2 1/4-20 X 3/4
9 060300 . PIN, CLEVIS 1 22 191045 ** PIVOT CAP COVER 1
10 052876 . BUMPER 1 22 402459 *** PIVOT CAP COVER 1
11 071377 . SCREW, 10-32 X 3/4 3 23 061716 *** SNAP RING 2
12 056200 . CLEVIS 1 24 402452 *** PIN 1
25 065603 ** SOCKET HEAD SCREW, 2
3/8-16 X 3/4
* HANDLE RETURN SPRING KIT PART NUMBER 901325
** USED ON TRUCKS SERIAL NUMBER 333423 TO 346936
EXCEPT FOR 346722, 346751, 346927, AND 346935
*** USED ON TRUCKS SERIAL NUMBER 346722, 346751,
346927, 346935, 346937 AND HIGHER
901630 12-7
R4013
12-8 901630
NOTES
901630 12-9
USED ON TRUCKS SERIAL BRAKE PAD KIT
NUMBERS 333423 TO 333640 PART NUMBER
EXCEPT 333432 800182 CONTAINS:
ITEM QTY
22 1
23 1
24 2
25 2
26 2
37 2
R357
12-10 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 056200 CLEVIS 1 20 502814 WELDMENT TUBE 1
2 060320 CLEVIS PIN 3 21 800119 CLEVIS 1
3 060417 COTTER PIN 10 22 052863* CLAMP, BRAKE 1
4 111104 UPPER PIVOT PLATE 1 23 052860* LEVER, BRAKE 1
5 053109 LOCK BUSHING 6 24 052859* PAD, BRAKE 2
6 053106 FLANGED BUSHING 2 25 052861* HEX HEAD BOLT 2
7 500201 TUBE BRAKE ROD 1 26 052862* NUT, BRAKE 2
8 111105 LOWER PIVOT PLATE 1 27 111706 PLATE, MOUNTING 1
9 500202 BRAKE ROD 1 28 077210 LOCK WAHSER, 5/16 6
10 500424 LOWER LEVER ASSY 1 29 063552 HEX HEAD CAP SCREW, 5/16 6
11 258107 PIVOT PIN 1 30 057903 KEY, 1/4 X 1/4 X 1 1
12 500197 MOUNTING BRACKET ASSY 1 31 503083 DISC ASSY 1
13 — HORN (FIGURE 12-55) REF 32 077215 LOCK WASHER 1
13 059634 NUT, HEX, NYLOK, 4-40 2 33 059645 NUT 1
14 077211 LOCK WASHER, 3/8 2 34 — SWITCH - DEADMAN REF
(FIGURE 12-55)
15 064605 HEX HEAD CAP SCREW 2
35 068336 ROUND HEAD SCREW, 2
16 258121 ROD 1
6-32 x 1-1/2
17 059427 HEX NUT 3
36 059412 HEX NUT 2
18 060310 CLEVIS PIN 1
37 075070* SPRING 2
19 060417 COTTER PIN 2
901630 12-11
USED ON TRUCKS SERIAL
NUMBERS 333432 AND
333641 AND HIGHER
R3297
12-12 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 053109 LOCK BUSHING 6 21 059645 NUT, 5/8-18 1
2 060417 COTTER PIN 10 22 077210 LOCK WAHSER, 5/16 4
3 053106 FLANGED BUSHING 2 23 063557 SCREW, CAP, HEX HD, 4
5/16-18 X 1-1/4
4 111104 UPPER PIVOT PLATE 1
24 077211 LOCK WASHER, 3/8 2
5 111105 LOWER PIVOT PLATE 1
25 064605 SCREW 1
6 060320 CLEVIS PIN 2
26 800119 CLEVIS 1
7 060218 CLEVIS PIN, 1/4 X 1 1
27 052821 DISC BRAKE CALIPER ASSY 1
8 500202 BRAKE ROD 1
28 059421 . NUT 2
9 505206 LEVER ASSEMBLY 1
29 077209 . LOCK WASHER 2
10 505199 BRACKET 1
30 901189 . BOLT 2
11 060310 CLEVIS PIN 1
31 901190 . SPACER 2
12 258127 PIN 1
32 901191 . SPRING 2
13 800284 CLEVIS 1
33 901188 . BRAKE PAD 1
14 059427 NUT, 5/16-24 2
34 901198 . C-RING 1
15 258126 ROD, THREADED 1
35 901197 . WASHER 1
16 500201 TUBE BRAKE ROD 1
36 901196 . SPRING 1
17 505208 * MOUNTING PLATE 1
37 901192 . BRAKE PAD WITH PIN 1
17 505215 ** MOUNTING PLATE 1
38 901195 . BRACKET 1
18 057903 KEY, 1/4 X 1/4 X 1 1
39 901194 . LEVER 1
19 505207 * DISC ASSEMBLY 1
40 901193 . WASHER 1
19 505214 ** DISC ASSEMBLY 1
20 077215 LOCK WASHER, 5/8 6
13 — HORN (FIGURE 12-55) REF
901630 12-13
R4702
12-14 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 506162 TRANSMISSION ASSEMBLY 25 064615 HEX HEAD CAP SCREW, 2
3/8-16 X 2-1/4
1 050700 . AXLE SHAFT 1
26 060428 . COTTER PIN 1
2 073504 . OIL SEAL 3
27 059745 . HEX NUT, 5/16-18 1
3 051112 . ROLLER BEARING CONE 2
28 057234 . MOTOR PINION SPUR 1
4 051111 . ROLLER BEARING CUP 2
5 026302 . DRAIN PLUG 1
29 — . NOT USED
30 060585 . DOWEL PIN 3
6 057210 . SPUR GEAR 1
31 800072 . TRANSMISSION HOUSING 1
7 077600 . LOCK WASHER 1
32 026304 . FILL PLUG 1
8 059680 . LOCKNUT 1
9 051126 . BALL BEARING 1
— 500935 DRIVE WHEEL ASSY 1
33 800035 . HUB 1
10 0557902 . SQUARE KEY, 5/16 X 1/38 1
34 079160 . POLYURETHANE WHEEL, 10-1/ 1
11 057211 . SPUR PINION 1
2 IN
12 057233 . INTERMEDIATE GEAR 1
35 077215 LOCK WASHER, 5/8 5
13 074701 . PINION SPACER 1
36 0646828 HEX HEAD CAP SCREW, 5
14 051125 . BALL BEARING 1
5/8-18 X 1
15 074706 . BEARING SPACER 1
37 042114 O-RING 1
16 036105 . COVER GASKET 1
38 — DRIVE MOTOR (FIGURE 12-51, REF
17 800073 . TRANSMISSION COVER 1 FIGURE 12-53)
18 077211 . LOCK WASHER 11 39 026704 STREET ELBOW, 3/8 1
19 064611 . HEX HEAD CAP SCREW, 7 40 076701 VENT 1
3/8-16 X 1-3/4
41 — NOT USED
20 036106 . BEARING COVER GASKET 1
42 021226 TERMINAL BLOCK 1
21 051159 . BEARING COVER 1 (RESISTOR SPEED
22 063555 . HEX HEAD CAP SCREW, 4 CONTROL)
5/16-18 X 1 43 068185 SCREW 4
23 077210 . LOCK WASHER, 5/16 4 44 077203 LOCK WASHER 4
24 064620 . HEX HEAD CAP SCREW, 2 45 059410 HEX NUT 4
3/8 X 3-3/4
901630 12-15
R3972
12-16 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 503014 CONTROL CABINET DOOR 1 14 077208 LOCK WASHER, NO. 10 4
2 059421 HEX NUT, 1/4-20 3 15 059416 HEX NUT, 10-32 4
3 077209 LOCK WASHER, 1/4 3 16 111752 ACCESS COVER 1
4 070476 ROUND HEAD MACHINE SCREW, 3 17 069478 FLAT HEAD MACHINE SCREW, 4
1/4-20 X 1/2 1/4-20 X 3/4
— 500422 BREATHER CAP & DIPSTICK 1 18 055500 LATCH 1
ASSY 19 — MAIN FRAME ASSY 1
5 250720 . DIPSTICK 1 20 — DECAL, 3-SPOOL VALVE REF
6 060937 . ROLL PIN, 1/8 X 5/8 1 (FIGURE 12-10)
7 029100 . BREATHER CAP 1 21 503390 * HYDRAULIC RESERVOIR 1
8 504025-01 HYDRAULIC ACCESS COVER 1 21 505831 ** HYDRAULIC RESERVOIR 1
9 003109 BATTERY, 12V, 450 AMP 1 22 069478 SCREW, 1/4-20 X 3/4 1
9 003124 BATTERY, 12V, 510 AMP 1 23 077209 LOCK WASHER 2
9 003145 BATTERY, 12V, 660 AMP 1 24 070476 SCREW, 1/4-20 X 1/2 1
9 003152 BATTERY, 24V, 220 AMP 1 25 059421 HEX NUT, 1/4-20 1
9 003140 BATTERY, 24V, 340 AMP 1 26 057508 GROMMET 1
9 003134 BATTERY, 24V, 510 AMP 1 27 052905 STRAIN RELIEF 1
10 504360-01 BATTERY SPACER ASSY 2 28 005421 BATTERY QUICK DISCONNECT 1
(6-12 IN WIDE 29 — CONNECTOR (FIGURE 12-55) REF
10 504360-03 BATTERY SPACER ASSY 2 30 — LIMIT SWITCH (FIGURE 12-13) REF
(10-15/16 IN WIDE 31 504054 HOUSING, 4 IN TANDEM 1
11 071376 TRUSS HEAD MACHINE SCREW, 4 33 501828 TRACTION HOUSING 1
10-32 X 1/2 34 068190 PHILLIPS HEAD SCREW, 6
12 058100 LATCH 1 4-40 X 1/4
13 069477 FLAT HEAD MACHINE SCREW, 2
1/4-20 X 1/2
* USED ON TRUCKS SERIAL NUMBER 333423 TO 356092
** USED ON TRUCKS SERIAL NUMBER 356093 AND HIGHER
901630 12-17
R3999
12-18 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 901179 DECAL KIT 1 9 056620 . WARNING DECAL 3
1 056564 . CAUTION DECAL 2 10 056625 . WARNING DECAL 2
2 056626 . OIL LEVEL 1 11 056590 . WARNING DECAL 1
3 056637-02 . TILT DECAL 2 12 056631 . DOOR DECAL 1
4 056637-03 . REACH DECAL 2 13 056636 . DECAL, 3-SPOOL 2
5 056637-01 . LIFT DECAL 2 — 056683 . DECAL, AMERICAN BUILT 2
6 056499 . NO RIDING DECAL 1 — 056696 . DECAL, BIG JOE SUPPORT 2
7 056494 . CAUTION DECAL 2 — 901201 PAINT, YELLOW (SPRAY CAN) A/R
8 056633 . MAST DECAL 2 — 901202 PAINT, BLACK (SPRAY CAN) A/R
901630 12-19
NOTES
12-20 901630
LOAD WHEEL KITS INCLUDE ITEMS 1 THRU 6
R3973
901630 12-21
R3273
12-22 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 062320 ROLLER ASSY 8 17 069607 FLAT HEAD CAP SCREW, 1
3/8-16 X 1-1/2
2 061023 ROLL PIN 1
18 077211 LOCKWASHER, 3/8 7
3 059447 HEX NUT, 3/4-16 2
19 077076 WASHER, FLAT 7 GA 1
4 077217 LOCKWASHER, 3/4 2
20 077077 SPACER, 9 GA AR
5 059547 JAM NUT, 3/4-16 2
20 077078 SPACER, 12 GA AR
6 060314 CLEVIS PIN W/RETAINING RING 4
20 077079 SPACER, 15 GA AR
7 312203 LIFT CHAIN ADJUSTING BOLT 2
20 077080 SPACER, 18 GA AR
8 313200 LIFT CHAIN (106” LIFT) 14.8 FT
21 313001 ANGLE BRACKET 1
8 313200 LIFT CHAIN (130” LIFT) 19.16 FT
22 064607 HEX HEAD CAP SCREW, 2
8 313200 LIFT CHAIN (154” LIFT) 22.79 FT
3/8-16 X 1-1/4
9 061729 SNAP RING 2
23 064609 HEX HEAD CAP SCREW 4
10 053013 WASHER 4
24 239520 CLAMP BAR 1
11 289202 SHEAVE 2
25 191162 BAR DRILLED 2
12 051210 BEARING 2
26 069607 FLAT HEAD SCREW 4
13 100016 WEAR SPEACER 1
27 402812 SHIM 4
14 504024 RAM HEAD WELDMENT 1
28 — INNER MAST ASSY 1
15 077213 LOCK WASHER, 1/2 1
29 — CYLINDER ASSY (FIGURE 12-37) REF
16 064711 HEX HEAD CAP SCREW 1
30 303601 SPINDLE 4
901630 12-23
R3274
12-24 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 077077 SPACER 9 GA AR 20 401943 SHEAVE PIN 2
1 077078 SPACER 12 GA AR 21 053013 THRUST WASHER, 12 GA 4
1 077079 SPACER 15 GA AR 21 053014 THRUST WASHER, 15 GA 4
1 077080 SPACER 18 GA AR 22 077209 LOCK WASHER, 1/4 3
2 062320 ROLLER ASSY 12 23 077031 WASHER 2
3 059547 JAM NUT, 3/4-16 2 24 051210 BEARING 4
4 059900 NUT WHEEL, 3/4-16 2 25 289202 SHEAVE 4
5 059437 NEX NUT, 1/2-13 4 26 289478 HEX HEAD CAP SCREW 2
6 059334 CHAIN MOUNT, LH 1 27 077213 LOCK WASHER, 1/2 4
7 312203 LIFT CHAIN ADJUSTING BOLT 2 28 059129 NUT 1
8 504335 CHAIN MOUNT, RH 1 29 401895 CARRIAGE STOP 2
9 060314 CLEVIS PIN W/RETAINING RING 4 30 077211 LOCK WASHER 4
10 064711 HEX HEAD CAP SCREW, 1/2-13 4 31 064609 HEX HEAD CAP SCREW 4
11 020703 SWITCH, CUTOUT 1 32 056585 TRIMAST DECAL 2
11 020689 * SWITCH, CUTOUT 1 33 056110 HOSE CLAMP 1
12 401921 MOUNTING PLATE, SWITCH 1 34 059421 HEX NUT, 1/4-20 1
13 005405 STRAIN RELIEF 1 35 069480 FLAT HEAD SCREW, 1/4-20 X 1 1
13 019910 * STRAIN RELIEF 1 36 056121 HOSE CLAMP 1
14 — OUTER MAST 1 37 403006 SPACER, CARRIAGE STOP AR
16 061023 ROLL PIN 1 38 — CYLINDER ASSY (FIGURE 12-38, REF
FIGURE 12-39, FIGURE 12-40)
17 061736 SNAP RING 1
39 313200 LIFT CHAIN (158” LIFT) 25.58 FT
18 025712 GREASE FITTING 4
39 313200 LIFT CHAIN (194” LIFT) 29.33 FT
19 061729 SNAP RING 2
40 — INNER-INNER MAST 1
41 303601 SPINDLES 8
* TRUCKS WQUIPPED WITH COLD CONDITIONING
901630 12-25
R3275
12-26 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 077077 SPACER 9 GA AR 13 051210 BEARING 2
1 077078 SPACER 12 GA AR 14 289202 SHEAVE 2
1 077079 SPACER 15 GA AR 15 061736 SNAP RING 2
1 077080 SPACER 18 GA AR 16 025712 GREASE FITTING 2
2 062320 ROLLER ASSY 12 17 503712 * SHEAVE COLLAR 1
3 312203 LIFT CHAIN ADJUSTING BOLT 2 17 505446 ** SHEAVE COLLAR 1
4 059547 JAM NUT, 3/4-16 2 18 060314 CLEVIS PIN W/RETAINING RING 4
5 077217 LOCK WASHER, 3/4 2 19 077211 LOCK WASHER, 3/8 5
6 077076 WASHER, FLAT 7 GA 1 20 064609 HEX HEAD CAP SCREW 4
7 064605 HEX HEAD CAP SCREW, 1 21 059447 NEX NUT, 3/4-16 2
3/8-16 X 1 22 403006 SPACER, CARRIAGE STOP AR
8 061020 ROLL PIN 1 23 — CYLINDER ASSY (FIGURE 12-41, REF
9 059129 NUT 1 FIGURE 12-42)
10 061023 ROLL PIN 1 24 — INNER MAST 1
11 401895 CARRIAGE STOP 2 25 313200 LIFT CHAIN (102” LIFT) 17.1 FT
12 053012 THRUST WASHER, 9 GA AR 25 313200 LIFT CHAIN (130” LIFT) 25.1 FT
12 053013 THRUST WASHER, 12 GA AR 26 303601 SPINDLES 4
* USED ON TRUCKS SERIAL NUMBER 333423 TO 335391
** USED ON TRUCKS SERIAL NUMBER 335392 AND HIGHER
901630 12-27
NOTES
12-28 901630
R3621M
901630 12-29
R3254
12-30 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505036-01 REACH ASSEMBLY 1 5 402817 . HEX HEAD CAP SCREW 2
(NON-TELESCOPIC) 6 077213 . LOCK WASHER 2
— 505036-02 REACH ASSEMBLY 1 7 064710 . HEX HEAD CAP SCREW 2
(TELESCOPIC) 8 — . REACH CYLINDER REF
— 505036-03 REACH ASSEMBLY 1 (FIGURE 12-33, FIGURE 12-34)
(FULL FREE LIFT) 9 505020 . OUTER STRUT 1
— 505036-04 REACH ASSEMBLY 1 10 402781 . PIVOT SHAFT 1
(TRIMAST)
11 025713 . GREASE FITTING 10
— 505875-01 * REACH ASSEMBLY 1
11 025713 * . GREASE FITTING 8
(NON-TELESCOPIC)
12 061706 . SNAP RING 10
— 505875-02 * REACH ASSEMBLY 1
13 077093 . THRUST WASHER 18
(TELESCOPIC)
14 402793 . HEX HEAD CAP SCREW 4
— 505875-03 * REACH ASSEMBLY 1
(FULL FREE LIFT) 15 505019 . INNER STRUT 1
901630 12-31
SEAL KIT FOR ALL SPOOLS
PART NO. 900368-03
12-32 901630
R4703
901630 12-33
12 7 13
8
14
15
16
11 17
3
4
10
5
9
8
7
6
19
20
21
1
R5980
12-34 901630
R6538
901630 12-35
3
6
R5978
R5979
1 4
Figure 12-22 Stack Valve Seal Kit
12-36 901630
NOTES
901630 12-37
R3245
Figure 12-23 Reservoir, Pump and Control Valve Hoses (PDR 20 Telescopic)
12-38 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — HYDRAULIC RESERVOIR REF 19 800144 COUPLING, MACHINED 1
(FIGURE 12-9) 20 026143 NIPPLE, 3/8, CLOSED 1
2 — BREATHER CAP AND DIP STICK REF 21 025505 ELBOW, 3/8, 90° 1
ASSEMBLY (FIGURE 12-9) 22 026109 NIPPLE, HOSE, 3/8 1
3 026506 BUSHING, REDUCER, 3/4 X 3/8 1 23 025114 ADAPTER, HEX, 3/8 (12 VOLT 1
4 025501 ELBOW, REDUCER, 3/4 X 3/8 1 TRUCKS OULY)
5 282500 TUBING, VINYL, 1/4 OD - 1/8 ID 8 FT 23 025111 FITTING, STRAIGHT, 3/8 (24 VOLT 1
6 026128 NIPPLE, HOSE, 3/8 2 TRUCKS ONLY)
7 056110 CLAMP, HOSE, SCREW TYPE 2 24 025131 ADAPTER, STRAIGHT, SWIVEL 1
NUT (12 VOLT TRUCKS ONLY)
8 308900 HOSE, RUBBER, LOW 1-1/4 FT
PRESSURE 24 025114 ADAPTER, HEX, 3/8 (12 VOLT 1
TRUCKS ONLY)
9 026707 ELBOW, STREET, 3/8 NPT 3
10 025111 FITTING, STRAIGHT, 3/8 2
25 — PUMP & MOTOR ASSY. REF
(FIGURE 12-47)
11 — VALVE (FIGURE 12-17, REF
26 800145 NIPPLE, MACHINED 1
FIGURE 12-20)
27 059628 NUT, CENTER LOCK, 5/16-18 2
12 025525 ELBOW, 3/8, JIC, 90° 1
28 400754 * PLACE, HOLD DOWN 1
13 026917 FITTING, HOSE, 3/8, JIC, SWIVEL 1
29 035108 * FILTER, SUMP 1
14 282900 HOSE, NEOPRENE, 3/4 AR
29 035114 ** FILTER, SUMP 1
15 026914 FITTING, HOSE, 3/8, MALE 1
30 042130 * O-RING 1
16 025107 CONNECTOR, SWIVEL, 3/8 1
(24 VOLT TRUCKS ONLY) 31 026302 PLUG 1
17 318200 HOSE, NEOPRENE, 3/4 1-1/2 FT
18 056105 CLAMP, HOSE, SCREW TYPE 2
* USED ON TRUCKS SERIAL NUMBER 333423 TO 356092
** USED ON TRUCKS SERIAL NUMBER 356093 AND HIGHER
901630 12-39
R3246
Figure 12-24 Reservoir, Pump and Control Valve Hoses (PDR 30 Telescopic)
12-40 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — HYDRAULIC RESERVOIR REF 18 504312-14 HOSE ASSEMBLY, 3/8 1
(FIGURE 12-9) 19 318200 HOSE, NEOPRENE, 3/4 1-1/2 FT
2 — BREATHER CAP AND DIP STICK REF 20 056105 CLAMP, HOSE, SCREW TYPE 2
ASSEMBLY (FIGURE 12-9) 21 025132 ADAPTER, HOSE, 3/4 X 3/4 1
3 026506 BUSHING, REDUCER, 3/4 X 3/8 1 (12 VOLT TRUCKS ONLY)
4 025501 ELBOW, REDUCER, 3/4 X 3/8 2 21 025133 ADAPTER, HOSE, 7/8 X 3/4 1
5 282500 TUBING, VINYL, 1/4 OD - 1/8 ID 9 FT (24 VOLT TRUCKS ONLY)
6 026143 NIPPLE, HOSE, 3/8, CLOSED 1 22 025131 ADAPTER, STRAIGHT, SWIVEL 1
NUT (12 VOLT TRUCKS ONLY)
7 308900 HOSE, RUBBER, 2 FT
LOW PRESSURE 22 025114 ADAPTER, HEX, 3/8 (24 VOLT 1
TRUCKS ONLY)
8 056110 CLAMP, HOSE, SCREW TYPE 4
23 025542 ELBOW, FEMALE 1
9 026128 NIPPLE, HOSE, 3/8 4
10 027107 TEE, HEAVY DUTY, 3/8 2
24 — PUMP & MOTOR ASSY. REF
(FIGURE 12-47)
11 026707 ELBOW, STREET, 3/8 NPT 3
25 800145 NIPPLE, MACHINED 1
12 308900 HOSE, RUBBER, 1 FT
26 059628 NUT, CENTER LOCK, 5/16-18 2
LOW PRESSURE
27 400754 * PLACE, HOLD DOWN 1
13 025111 FITTING, STRAIGHT, 3/8 2
28 035108 * FILTER, SUMP 1
14 — VALVE (FIGURE 12-17, REF
FIGURE 12-20) 28 035114 ** FILTER, SUMP 1
15 048160 RELIEF VALVE 1 29 042130 * O-RING 1
16 026109 NIPPLE, HOSE, 3/8 2 30 026114 NIPPLE, CLOSED, 3/8 1
17 026912 CONNECTOR, STRAIGHT, 3/8 JIC 1 31 026302 PLUG 1
901630 12-41
R3247
Figure 12-25 Reservoir, Pump and Control Valve Hoses (PDR 20 Trimast and Full Free Lift)
12-42 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — HYDRAULIC RESERVOIR REF 17 318200 HOSE, NEOPRENE, 3/4 1
(FIGURE 12-9) 18 056105 CLAMP, HOSE, SCREW TYPE 2
2 — BREATHER CAP AND DIP STICK REF 19 800144 COUPLING, MACHINED 1
ASSEMBLY (FIGURE 12-9) 20 026143 NIPPLE, HOSE, 3/8, CLOSED 1
3 026506 BUSHING, REDUCER, 3/4 X 3/8 1 21 025505 ELBOW, 3/8, 90° 1
4 026303 PLUG, 1/4 1 22 025114 ADAPTER, HOSE, 3/8 1
5 026128 NIPPLE, HOSE, 3/8 2 (12 VOLT TRUCKS ONLY)
6 056110 CLAMP, HOSE, SCREW TYPE 2 22 025111 ADAPTER, HOSE, 3/8 1
7 308900 HOSE, RUBBER, 1 (24 VOLT TRUCKS ONLY)
LOW PRESSURE 23 — PUMP & MOTOR ASSY. REF
8 026707 ELBOW, STREET, 3/8 NPT 2 (FIGURE 12-47)
9 025111 FITTING, STRAIGHT, 3/8 2 24 800145 NIPPLE, MACHINED 1
10 — VALVE (FIGURE 12-17, REF 25 059628 NUT, CENTER LOCK, 5/16-18 2
FIGURE 12-20) 26 400754 * PLACE, HOLD DOWN 1
11 025525 ELBOW, 3/8, JIC, 90° 2 27 035108 * FILTER, SUMP 1
12 026917 FITTING, HOSE, 3/8, 2 27 035114 ** FILTER, SUMP 1
JIC, SWIVEL 28 042130 * O-RING 1
13 282900 HOSE, NEOPRENE, 3/4 AR 29 026302 PLUG 1
14 035113 FILTER 1
15 026109 NIPPLE, HOSE, 3/8 2
16 025131 ADAPTER, STRAIGHT, SWIVEL 1
NUT (12 VOLT TRUCKS ONLY)
16 025114 ADAPTER, HEX, 3/8 (24 VOLT 1
TRUCKS ONLY)
* USED ON TRUCKS SERIAL NUMBER 333423 TO 356092
** USED ON TRUCKS SERIAL NUMBER 356093 AND HIGHER
901630 12-43
R3248
Figure 12-26 Reservoir, Pump and Control Valve Hoses (PDR 30 Trimast and Full Free Lift)
12-44 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — HYDRAULIC RESERVOIR REF 18 504312-12 HOSE ASSEMBLY, 3/8 1
(FIGURE 12-9) 19 282900 HOSE, NEOPRENE, 3/4 AR
2 — BREATHER CAP AND DIP STICK REF 20 056105 CLAMP, HOSE, SCREW TYPE 2
ASSEMBLY (FIGURE 12-9) 21 025132 ADAPTER, HOSE, 3/4 X 3/4 1
3 026506 BUSHING, REDUCER, 3/4 X 3/8 1 (12 VOLT TRUCKS ONLY)
4 026303 PLUG, 1/4 1 21 025133 ADAPTER, HOSE, 7/8X 3/4 1
5 035113 FILTER 1 (24 VOLT TRUCKS ONLY)
6 026143 NIPPLE, HOSE, 3/8, CLOSED 1 22 025131 ADAPTER, STRAIGHT, SWIVEL 1
NUT (12 VOLT TRUCKS ONLY)
7 308900 HOSE, RUBBER, 2 FT
LOW PRESSURE 22 025114 ADAPTER, HEX, 3/8 (24 VOLT 1
TRUCKS ONLY)
8 056110 CLAMP, HOSE, SCREW TYPE 4
23 026114 NIPPLE, CLOSE, 3/8 1
9 026128 NIPPLE, HOSE, 3/8 4
10 027107 TEE, HEAVY DUTY, 3/8 2
24 — PUMP & MOTOR ASSY. REF
(FIGURE 12-47)
11 026707 ELBOW, STREET, 3/8 NPT 4
25 800145 NIPPLE, MACHINED 1
12 308900 HOSE, RUBBER, 2 FT
26 059628 NUT, CENTER LOCK, 5/16-18 2
LOW PRESSURE
27 400754 * PLATE, HOLD DOWN 1
13 025111 FITTING, STRAIGHT, 3/8 2
28 035108 * FILTER, SUMP 1
14 — VALVE (FIGURE 12-17, REF
FIGURE 12-20) 28 035114 ** FILTER, SUMP 1
15 048160 RELIEF VALVE 1 29 042130 * O-RING 1
16 026109 NIPPLE, HOSE, 3/8 2 30 026302 PLUG 1
17 026912 CONNECTOR, STRAIGHT, 3/8 JIC 2
* USED ON TRUCKS SERIAL NUMBER 333423 TO 356092
** USED ON TRUCKS SERIAL NUMBER 356093 AND HIGHER
901630 12-45
R3249
Figure 12-27 Control Valve to Lift Cylinder and Reach Cylinder (PDR 20 and 30 Telescopic)
12-46 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 026916 FITTING HOSE, 1/4 JIC SWIVEL 6 17 059421 NUT, HEX, 1/4-20 4
2 025120 ELBOW, SWIVEL NUT, 3/8, 90° 3 18 026912 CONNECTOR, STRAIGHT, 3/8 JIC 1
3 026911 CONNECTOR, STRAIGHT, 3 19 026504 BUSHING, REDUCING, 1/2 TO 3/8 2
3/8, JIC (24 VOLT TRUCKS ONLY)
4 — VALVE (FIGURE 12-17, REF 20 047104 REGULATOR, FLOW, 5 GPM 1
FIGURE 12-20) (12 VOLT TRUCKS ONLY)
5 025113 ADAPTER REDUCER, 9/16 TO 1/4 3 20 047107 VALVE, FLOW REGULATOR, 1
7 GPM (24 VOLT TRUCKS ONLY)
6 026708 ELBOW, 90° STREET, 1/4 1
21 026707 ELBOW, STREET, 3/8 NPT, 90° 2
7 025121 ELBOW, 3/8, JIC, 90° 1
8 026104 NIPPLE, 1/4 HD, CLOSE 1 22 026116 NIPPLE, 3/8 X 3, EX HEAVY DUTY 1
23 026926 FITTING, HOSE (PDR 20) 2
9 048134 VALVE, RESTRICTOR 1
10 026910 CONNECTOR, MALE, 1/4 TUBE 11 23 026916 FITTING, HOSE (PDR 30) 2
901630 12-47
R3250
Figure 12-28 Control Valve to Lift Cylinder and Reach Cylinder (PDR 20 and 30 Trimast)
12-48 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 026916 FITTING HOSE, 1/4 JIC SWIVEL 16 17 069481 SCREW, PH FL HD, 1/4-20 X 1-1/4 4
2 025120 ELBOW, SWIVEL NUT, 3/8, 90° 3 18 059429 NUT, HEX, 3/8-16 4
3 026911 CONNECTOR, STRAIGHT, 3 19 077211 WASHER 4
3/8, JIC 20 026303 PLUG, 1/4 4
4 — VALVE (FIGURE 12-17, REF 21 504328 MANIFOLD 2
FIGURE 12-20) 22 063607 HEX HEAD SCREW 4
5 025113 ADAPTER REDUCER, 9/16 TO 1/4 3 23 063482 HEX HEAD SCREW, 8
6 025121 ELBOW, 3/8, JIC, 90° 1 1/4-20 X 1-1/4
7 026708 ELBOW, 90° STREET, 1/4 1 24 401942 SPACER 4
8 026104 NIPPLE, 1/4 HD, CLOSE 1 25 401940 SHEAVE 4
9 048134 VALVE, RESTRICTOR 1 26 401941 BOLT, SHPULDER 4
10 026910 CONNECTOR, MALE, 1/4 TUBE 16 27 025542 ELBOW, 90° 1
11 504272-01 HOSE (158 IN. LIFT) 1 28 026116 NIPPLE, 3/8 X 3 1
11 504272-02 HOSE (194 IN. LIFT) 1 29 026119 NIPPLE, 3/8 X 2 1
12 282800 HOSE, HYDRAULIC, DOUBLE AR 30 026707 ELBOW, 90° 1
13 063480 HEX HEAD CAP SCREW, 4 32 025505 ELBOW, 90° 1
1/4-20 X 1 35 026312 PLUG, 1/8 1
14 077209 WASHER, LOCK, SPLIT, 1/4 16 36 504329 COLLAR 1
15 401894 CLAMP, HOSE 8 37 025712 FITTING, GREASE 2
16 059421 NUT, HEX, 1/4-20 8 38 504314-10 HOSE ASSEMBLY 4
901630 12-49
R3251
Figure 12-29 Control Valve to Lift Cylinder and Reach Cylinder (PDR 20 and 30 Full Free Lift)
12-50 901630
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 026916 FITTING HOSE, 1/4 JIC SWIVEL 8 17 063482 HEX HEAD SCREW, 8
1/4-20 X 1-1/4
2 025120 ELBOW, SWIVEL NUT, 3/8, 90° 3
18 026924 FITTING HOSE 4
3 026911 CONNECTOR, STRAIGHT, 3
3/8, JIC 19 061607 MANIFOLD 1
4 — VALVE (FIGURE 12-17, REF 20 026923 FITTING 4
FIGURE 12-20) 21 064605 HEX HEAD SCREW, 3/8-16 X 1 4
5 025113 ADAPTER REDUCER, 9/16 TO 1/4 3 22 077087 WASHER 4
6 025121 ELBOW, 3/8, JIC, 90° 1 23 061606 MANIFOLD 1
7 026708 ELBOW, 90° STREET, 1/4 1 24 077211 WASHER 8
8 026104 NIPPLE, 1/4 HD, CLOSE 1 25 059429 NUT, 3/8-16 4
9 048134 VALVE, RESTRICTOR 1 26 026312 PLUG, 1/8 1
10 026910 CONNECTOR, MALE, 1/4 TUBE 1 27 026711 ELBOW 2
11 504264-03 HOSE ASSEMBLY 1 28 026109 NIPPLE, HOSE, 3/8 1
(12 VOLT TRUCKS ONLY) 29 025542 ELBOW, 90° 1
11 504264-04 HOSE ASSEMBLY 1 30 063603 HEX HEAD CAP SCREW 4
(24 VOLT TRUCKS ONLY)
31 504268 BRACKET 2
12 282800 HOSE, HYDRAULIC, DOUBLE AR
32 026925 FITTING, HOSE 4
13 063480 HEX HEAD CAP SCREW, 4
33 025120 ELBOW, SWIVEL NUT, 3/8, 90° 6
1/4-20 X 1
34 505029-01 HOSE ASSEMBLY 1
14 077209 WASHER, LOCK, SPLIT, 1/4 12
35 505029-02 HOSE ASSEMBLY 1
15 401894 CLAMP, HOSE 6
36 505029-03 HOSE ASSEMBLY 1
16 057508 GROMMET 1
37 505029-04 HOSE ASSEMBLY 1
901630 12-51
R3252
12-52 901630
R3253
9 025113 REDUCER 2
27 — BACK FRAME (FIGURE 12-16) REF
10 077209 LOCKWASHER 11
28 — INNER STRUT (FIGURE 12-16) REF
— 31 077030 SPACER 2
13 HOSE (FIGURE 12-32) REF
14 800276-02 CLAMP 2
32 — MANIFOLD, REACH EXTEND REF
(FIGURE 12-30)
15 063478 HEX HEAD CAP SCREW 3
32 — MANIFOLD, REACH RETRACT REF
16 800276-01 CLAMP 1
(FIGURE 12-30)
17 056137-01 STRAP 6
* USED ON TRUCKS SERIAL NUMBER 333423 TO 360543
** USED ON TRUCKS SERIAL NUMBER 360544 AND HIGHER
901630 12-53
12-54 901630
R4119
901630 12-55
USED ON TRUCKS SERIAL
NUMBERS 333423 TO 338311
PACKING KIT
901312 CONTAINS:
ITEM QTY
3 3
4 2
6 1
7 1
9 1
10 1
12 1
R3976
12-56 901630
USED ON TRUCKS SERIAL
NUMBERS 338312 AND HIGHER
PACKING KIT
901431 CONTAINS:
ITEM QTY
3 3
4 2
6 1
7 1
10 1
12 1
R4343
901630 12-57
USED ON TRUCKS SERIAL
NUMBERS 333423 TO 338311
PACKING KIT
901313 CONTAINS:
ITEM QTY
3 3
4 2
7 1
8 1
9 1
11 1
12 1
R3975
12-58 901630
USED ON TRUCKS SERIAL
NUMBERS 338312 AND HIGHER
PACKING KIT
901424 CONTAINS:
ITEM QTY
3 3
4 2
6 1
8 1
11 1
12 1
R4344
901630 12-59
USED ON TRUCKS
SERIAL NUMBERS
333423 TO 371487
ORDER RETROFIT
KIT 907120
R6107
14 1 15 1
15 1
Figure 12-37. Lift Cylinder - Telescopic
12-60 901630
USED ON 158 INCH TRUCKS SERIAL
NUMBERS 333423 TO 335477
R3631A
901630 12-61
USED ON 158 INCH TRUCKS SERIAL
NUMBERS 335478 TO 342111
R4335
12-62 901630
USED ON 158 INCH TRUCKS SERIAL
NUMBERS 342112 AND HIGHER
R1898
LIFT HEIGHT
INDEX (INCHES)
NO. PART NAME 158 QTY
PART NO.
— LIFT CYLINDER ASSY 504490 1
1 . OUTSIDE TUBE 906050 1
2 . PRIMARY ROD 906054 1
3 . SECONDARY ROD 906058 1
4 . GLAND NUT 906061 1
5 . GLAND NUT 906063 1
6 . FLOW REGULATOR 906065 1
7 . BASE 906067 1
NOTE: ALL ILLUSTRATED PARTS NOT NUMBERED ARE IN PACKING
KIT PART NUMBER 900961.
901630 12-63
USED ON TRUCKS SERIAL
NUMBERS 333423 TO 335391
R3631A
12-64 901630
USED ON TRUCKS SERIAL
NUMBERS 335392 AND HIGHER
R4335
901630 12-65
R3260
12-66 901630
R3261
901630 12-67
R3258
12-68 901630
R3259
901630 12-69
R295, R429
12-70 901630
USED ON TRUCKS
SERIAL NUMBER
333423 TO 334371
MOTOR KIT
901368 CONTAINS:
ITEM QTY
3 1
4 1
5 1
R1732
9 1
901630 12-71
USED ON TRUCKS
SERIAL NUMBER
334372 AND HIGHER
MOTOR KIT
901445 CONTAINS:
ITEM QTY
4 1
5 1
7 1
R4084
14 1
12-72 901630
MOTOR KIT
901369 CONTAINS:
ITEM QTY
10 1
12 1
16 1
R1263
19 1
901630 12-73
NOTES
MOTOR KIT
901373 CONTAINS:
ITEM QTY
3 1
7 1
11 1
13 1
R1189
12-74 901630
USED ON 12 VOLT TRUCKS
SERIAL NUMBER
377970 AND HIGHER
R6540
901630 12-75
USED ON 24 VOLT TRUCKS
SERIAL NUMBER
344279 TO 376086
R6503
12-76 901630
USED ON 24 VOLT TRUCKS
SERIAL NUMBER
376087 AND HIGHER
R6250
901630 12-77
1. SEE SUPPLEMENT 187 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 333423 TO 334630
2. SEE SUPPLEMENT 220 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 334631 AND
HIGHER
R3262
901630 12-79
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — CONTACTOR PANEL, REF 16 077207 WASHER, LOCK, SPLIT #10 2
12-VOLT (FIGURE 12-56) 17 071376 SCREW-TRUSS, #10-32 X 1/2 2
1 — CONTACTOR PANEL, REF 18 077209 WASHER, LOCK, SPLIT, 1/4 3
24-VOLT (FIGURE 12-57) 19 059421 NUT, HEX, 1/4-20 1
2 077211 WASHER, LOCK, SPLIT, 3/8 4 20 056113 TIE-WIRE, NYLON 4
3 059429 NUT, HEX, 3/8-16 4 21 023018 WIRE A/R
4 056135 CLAMP, LOOP 1 22 020729 SWITCH-DEADMAN 1
5 077030 WASHER 3 22 020690 * SWITCH-DEADMAN 1
6 063478 SCREW, HEX HEAD, CAP, 1 23 005405 STRAIN RELIEF 2
1/4-20 X 3/4
23 019910 * STRAIN RELIEF 2
7 023025 WIRE HARNESS ASSEMBLY 1
24 023117 WIRE HARNESS, DEADMAN 1
8 076200 TUBING, ZIPPER A/R
25 005401 CONNECTOR, GREY ANDERSON 1
9 059410 NUT, HEX ZINC, 5-40 4
26 068480 SCREW, MACHINE, DOTTED, 2
10 068185 SCREW, SLOTTED, 4 ROUND HEAD
ROUND HEAD
27 401921 BRACKET, MOUNTING SWITCH 1
11 077203 WASHER, LOCK, SPLIT #5 4
28 020703 SWITCH, LIMIT 1
12 021204 TERMINAL, QUICK CONNECT, 1
29 021236 TERMINAL, RING #6, 16 GA 2
FEMALE
30 063477 SCREW, HX HD, CAP, 1/4-20 X 3/8 2
13 023083 WIRE HARNESS 2
31 0575008 GROMMET 1
14 021724 TERMINAL BOARD, SPADE 12 1
32 009600 HORN, 12-VOLT 1
15 020719 SOLENOID, 12-VOLT 1
32 009602 HORN, 24-VOLT 1
15 020715 SOLENOID, 24-VOLT 1
12-80 901630
1. SEE SUPPLEMENT 187 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 333423 TO 334630
2. SEE SUPPLEMENT 221 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 334631 TO 374310
3. SEE SUPPLEMENT 348 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 374311 AND
HIGHER
R1864
901630 12-81
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 504652 12-VOLT ELECTRICAL 1 26 070488 . SCREW 3
CONTROL PANEL ASSEMBLY 27 023130 . HARNESS ASSEMBLY 1
1 504638 . PANEL 1 28 056515 . DECAL, FUSE 1
2 250716 . BRACKET 2 29 070491 . SCREW 10
3 071376 . SCREW, 1-32 x 1/2 3 30 — . CONTACTOR ASSEMBLY REF
4 077208 . LOCKWASHER, SPLIT 3/16 3 (FIGURE 12-59)
5 070475 . SCREW, 1/4-20 X 3/8 4 31 021226 . TERMINAL 1
6 077209 . LOCKWASHER, SPLIT 1/4 10 32 — . CONTACTOR ASSEMBLY REF
(FIGURE 12-60)
7 — . RESISTOR, 12 VOLT REF
(FIGURE 12-58) 33 401181 . BUS BAR 1
8 021221 . TERMINAL 3 34 056507 . DECAL FUSE 1
9 503774 . CABLE ASSEMBLY 3 35 077205 . WASHER 10
10 023026 . WIRE AR 36 021204 . TERMINAL 5
11 021238 . TERMINAL 4 37 021206 . TERMINAL 1
12 021237 . TERMINAL 2 38 023018 . WIRE AR
13 068177 . SCREW MACHINE, 5-40 X 3/8 2 39 503965-37 . CABLE ASSEMBLY, A-2 1
14 077203 . LOCKWASHER, SPLIT, NO. 5 5 40 503965-36 . CABLE ASSEMBLY, A-1 1
15 059410 . NUT, 5-40 5 41 503965-42 . CABLE ASSEMBLY, F-2 1
16 018907 . RESISTOR 1 42 503965-39 . CABLE ASSEMBLY 1
17 504639 . CABLE ASSEMBLY 1 43 504277-01 . CABLE ASSEMBLY 1
18 010614 . STAND OFF 3 44 503965-38 . CABLE ASSEMBLY, F-1 1
19 070489 . SCREW 3 45 503965-40 . CABLE ASSEMBLY 1
20 077105 . WASHER, FLAT, BRONZE 6 46 504277-02 . CABLE ASSEMBLY 1
21 008904 . FUSE BLOCK 1 47 056120 . CLAMP 1
22 008910 . FUSE, 15-AMP 1 48 021712-01 . TIME DELAY, 1-SEC 1
23 056504 . DECAL, FUSE 1 49 021712-02 . TIME DELAY, 2-SEC 1
24 068179 . SCREW, 5-40 X 5/8 3 50 008917 . FUSE, 40-AMP DYNAMIC 1
BRAKE
25 008906 . FUSE, 300-AMP 1
A/R - AS REQUIRED
12-82 901630
1. SEE SUPPLEMENT 187 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 333423 TO 334630
2. SEE SUPPLEMENT 221 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 334631 TO 374310
3. SEE SUPPLEMENT 348 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 374311 AND
HIGHER
R1863
901630 12-83
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 504653 24-VOLT ELECTRICAL 1 24 068179 . SCREW, 5-40 X 5/8 3
CONTROL PANEL ASSEMBLY 25 008906 . FUSE, 300-AMP 1
1 504638 . PANEL 1 26 070488 . SCREW 3
2 250716 . BRACKET 2 27 023130 . HARNESS ASSEMBLY 1
3 071376 . SCREW, 1-32 x 1/2 3 28 056515 . DECAL, FUSE 1
4 077208 . LOCKWASHER, SPLIT 3/16 3 29 070491 . SCREW 10
5 070475 . SCREW, 1/4-20 X 3/8 4 30 — . CONTACTOR ASSEMBLY REF
6 077209 . LOCKWASHER, SPLIT 1/4 10 (FIGURE 12-59)
7 — . RESISTOR, 12 VOLT REF 31 021226 . TERMINAL 1
(FIGURE 12-58) 32 — . CONTACTOR ASSEMBLY REF
8 021221 . TERMINAL 3 (FIGURE 12-60)
9 503774 . CABLE ASSEMBLY 3 33 401181 . BUS BAR 1
10 023026 . WIRE AR 34 056507 . DECAL FUSE 1
11 021238 . TERMINAL 4 35 077205 . WASHER 10
12 056120 . CLAMP 1 36 021204 . TERMINAL 5
13 021710 . TIME DELAY, 2-SEC 1 37 021206 . TERMINAL 1
14 077203 . LOCKWASHER, SPLIT, NO. 5 5 38 023018 . WIRE AR
15 059410 . NUT, 5-40 5 39 503965-37 . CABLE ASSEMBLY, A-2 1
16 021712-01 . TIME DELAY, 1-SEC 1 40 503965-36 . CABLE ASSEMBLY, A-1 1
17 504639 . CABLE ASSEMBLY 1 41 503965-42 . CABLE ASSEMBLY, F-2 1
18 010614 . STAND OFF 3 42 503965-39 . CABLE ASSEMBLY 1
19 070489 . SCREW 3 43 504277-03 . CABLE ASSEMBLY 1
20 077105 . WASHER, FLAT, BRONZE 6 44 503965-38 . CABLE ASSEMBLY, F-1 1
21 008904 . FUSE BLOCK 1 45 503965-40 . CABLE ASSEMBLY 1
22 008910 . FUSE, 15-AMP 1 46 504277-02 . CABLE ASSEMBLY 1
23 056504 . DECAL, FUSE 1 47 008917 . FUSE, 40-AMP DYNAMIC 1
BRAKE
A/R - AS REQUIRED
12-84 901630
R5919
901630 12-85
NOTES
12-86 901630
CONTACTOR TIP KIT
PART NUMBER 1. SEE SUPPLEMENT 221 FOR TRANSISTOR
901531-08 CONTAINS: TRUCKS SERIAL NUMBER 334631 TO 374310
ITEM QTY 2. SEE SUPPLEMENT 348 FOR TRANSISTOR
3 1 TRUCKS SERIAL NUMBER 374311 AND
5 1 HIGHER
8 1
12 1
R1865
901630 12-87
CONTACTOR TIP KIT
1. SEE SUPPLEMENT 221 FOR TRANSISTOR
PART NUMBER
TRUCKS SERIAL NUMBER 334631 TO 374310
901531-09 CONTAINS:
2. SEE SUPPLEMENT 348 FOR TRANSISTOR
ITEM QTY
TRUCKS SERIAL NUMBER 374311 AND
3 1
HIGHER
5 1
8 1
12 1
16 1
R1866
12-88 901630
R4118
901630 12-89
R4704
12-90 901630
1. SEE SUPPLEMENT 221 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 334631 TO 374310
2. SEE SUPPLEMENT 348 FOR TRANSISTOR
TRUCKS SERIAL NUMBER 374311 AND
HIGHER
R1517
901630 12-91
R3263
12-92 901630
NOTES
901630 12-93
Big Joe Manufacturing Company