SSC Series - Big Lift, LLC Support Site for Big Joe … · Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901270 Rev C 07/28/2006 SSC Series TELESCOPIC STOCK SELECTOR,

Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901270Rev C 07/28/2006

SSC SeriesTELESCOPIC STOCK SELECTOR,

COUNTERBALANCED LIFT TRUCKSerial Number 379414 and Higher

Operation

Maintenance

Repair Parts List

TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 1-11-2. GENERAL DESCRIPTION. . . . . . . . . . . . . 1-11-2.1. WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21-3. SAFETY FEATURES . . . . . . . . . . . . . . . . . 1-21-4. OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21-5. SAFETY SYMBOLS. . . . . . . . . . . . . . . . . . 1-2

2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-2. OPERATING PRECAUTIONS.. . . . . . . . . . 2-12-3. BEFORE OPERATION. . . . . . . . . . . . . . . . 2-22-4. INSTRUMENTS AND CONTROLS . . . . . . 2-42-4.1. FULL FEATURE DISPLAY. . . . . . . . . . . . . 2-52-5. OPERATION . . . . . . . . . . . . . . . . . . . . . . . 2-72-5.1. DRIVING AND STOPPING

PROCEDURES . . . . . . . . . . . . . . . . . . . . . 2-72-5.2. BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72-5.3. OPERATING LIFT . . . . . . . . . . . . . . . . . . . 2-72-5.4. FORK LOADING . . . . . . . . . . . . . . . . . . . . 2-82-5.5. PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92-5.6. EMERGENCY POWER DISCONNECT . . . 2-92-5.7. MOVING A DISABLED TRUCK . . . . . . . . . 2-9

3 PLANNED MAINTENANCE . . . . . . . . . . . . . . . . . . . 3-13-1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-2. PERIODIC CHECKS. . . . . . . . . . . . . . . . . . 3-13-3. BATTERY CARE. . . . . . . . . . . . . . . . . . . . . 3-13-3.1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 3-13-3.2. BATTERY SERVICING. . . . . . . . . . . . . . . . 3-23-4. LUBRICATION. . . . . . . . . . . . . . . . . . . . . . 3-23-4.1. HYDRAULIC SYSTEM CAPACITY . . . . . . 3-23-5. LIFT CHAIN MAINTENANCE. . . . . . . . . . . 3-23-6. THROTTLE CONTROL LUBRICATION. . . 3-3

4 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . 4-14-1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . 4-14-2. POWER STEERING REGULATOR . . . . . . 4-34-3. POWERPACK CONTROLLER. . . . . . . . . . 4-54-3.1. CAN (CONTROLLER AREA NETWORK)

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . 4-74-3.2. DIAGNOSTICS AND

TROUBLESHOOTING . . . . . . . . . . . . . . . . 4-8

5 STEERING SYSTEM MAINTENANCE . . . . . . . . . . 5-15-1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 5-15-2. STEERING ELECTRICAL CABLE. . . . . . . 5-15-2.1. CABLE TENSION ADJUSTMENT . . . . . . . 5-15-2.2. UPPER CABLE REPLACEMENT. . . . . . . . 5-25-2.3. LOWER CABLE REPLACEMENT . . . . . . . 5-35-3. STEERING WHEEL AND COLUMN. . . . . . 5-45-3.1. STEERING WHEEL COLUMN REMOVAL 5-45-3.2. STEERING WHEEL COLUMN

INSTALLATION . . . . . . . . . . . . . . . . . . . . . 5-45-3.3. STEERING CENTERING ADJUSTMENT . 5-45-4. STEERING REGULATOR . . . . . . . . . . . . . 5-5

5-4.1. REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 5-55-4.2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 5-55-5. STEERING REFERENCE SWITCH . . . . . . 5-55-5.1. REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 5-55-5.2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 5-5

6 BRAKE SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . 6-16-1. BRAKE PEDAL SWITCH ADJUSTMENT. . 6-16-2. BRAKE ASSEMBLY REPLACEMENT . . . . 6-2

7 TRANSMISSION, DRIVE WHEEL, AND LOAD WHEEL SERVICING . . . . . . . . . . . . . . . . . . . 7-17-1. DRIVE WHEEL REPLACEMENT. . . . . . . . 7-17-2. TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 7-17-2.1. REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 7-17-2.2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7-17-3. LOAD WHEEL REPLACEMENT. . . . . . . . . 7-3

8 ELEVATION SYSTEM SERVICING. . . . . . . . . . . . . 8-18-1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 8-18-2. LIFT CHAIN ADJUTSTMENT . . . . . . . . . . . 8-18-3. LIFT CHAIN WEAR INSPECTION . . . . . . . 8-28-4. LIFT CHAIN REPLACEMENT . . . . . . . . . . 8-28-5. RAM HEAD REPLACEMENT. . . . . . . . . . . 8-28-6. LIFT CYLINDER REPLACEMENT. . . . . . . 8-28-7. LIFT CARIAGE REMOVAL. . . . . . . . . . . . . 8-38-8. LIFT CARIAGE DISASEMBLY. . . . . . . . . . 8-4

9 HYDRAULIC SYSTEM SERVICING . . . . . . . . . . . . 9-19-1. GERNERAL. . . . . . . . . . . . . . . . . . . . . . . . . 9-19-2. SUMP FILTER REPLACEMENT. . . . . . . . . 9-29-3. HANDUP VALVE REPLACEMENT. . . . . . . 9-29-4. ACCUMULATOR SERVICING AND

RECHARGING . . . . . . . . . . . . . . . . . . . . . . 9-29-4.1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 9-29-4.2. PRECHARGE ADJUSTMENT . . . . . . . . . . 9-29-5. HYDRAULIC PRESSURE ADJUSTMENT . 9-39-6. THROTTLE VALVE ADJUSTMENT . . . . . . 9-49-7. THROTTLE VALVE REPLACEMENT . . . . 9-59-8. THROTTLE VALVE ACTUATOR REPAIR . 9-59-9. FLOW REGULATOR VALVE

REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 9-69-10. HYDRAULIC PUMP AND MOTOR

ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 9-69-11. LIFT CYLINDER REPAIR . . . . . . . . . . . . . . 9-8

10 ELECTRICAL COMPONENTS. . . . . . . . . . . . . . . . 10-110-1. HIGH SPEED LIMIT SWITCH. . . . . . . . . . 10-110-1.1. OPERATIONAL CHECK. . . . . . . . . . . . . . 10-110-1.2. HIGH SPEED LIMIT SWITCH

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 10-110-2. EMERGENCY POWER DISCONNECT . . 10-110-2.1. DISCONNECT SWITCH . . . . . . . . . . . . . . 10-110-2.2. RESET SWITCH. . . . . . . . . . . . . . . . . . . . 10-110-2.3. EPD PANEL ASSEMBLY . . . . . . . . . . . . . 10-110-3. ELECTRICAL CONTROL PANEL . . . . . . 10-410-3.1. ELECTRICAL PANEL ASSEMBLY. . . . . . 10-4

901270 i

TABLE OF CONTENTS - Continued

Section Page Section Page

10-4. JOYSTICK CONTROLLER . . . . . . . . . . . 10-510-4.1. REPLACEMENT . . . . . . . . . . . . . . . . . . . 10-510-5. FULL FEATURE DISPLAY . . . . . . . . . . . 10-510-6. ELECTRICAL CABLE MAINTENANCE . . 10-510-6.1. ELECTRICAL CABLE TENSION

ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . 10-510-6.2. REPLACEMENT OF ELECTRICAL

CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-610-7. PUMP MOTOR . . . . . . . . . . . . . . . . . . . . 10-710-8. DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . 10-710-8.1. MOTOR REMOVAL . . . . . . . . . . . . . . . . . 10-710-8.2. MOTOR REPAIR . . . . . . . . . . . . . . . . . . . 10-7

11 OPPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . 11-111-1. FLASHING RED LIGHT. . . . . . . . . . . . . . 11-111-2. SIDE GUIDE ROLLERS. . . . . . . . . . . . . . 11-111-2.1. STEEL ROLLER REPLACEMENT. . . . . . 11-111-2.2. POLYURETHANE ROLLER

REPLACEMENT. . . . . . . . . . . . . . . . . . . . 11-111-3. SAFETY HARNESS . . . . . . . . . . . . . . . . . 11-211-4. SAFETY BELT . . . . . . . . . . . . . . . . . . . . . 11-211-5. PALLET CLAMP. . . . . . . . . . . . . . . . . . . . 11-311-6. SLIP ON PLATFORM. . . . . . . . . . . . . . . . 11-4

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

LIST OF ILLUSTRATIONS

Figure Page Figure Page

A SUPPORTING CLAMP. . . . . . . . . . . . . . . . . . . . 2-11-1 NAME PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11-2 LOAD CENTER OF GRAVITY . . . . . . . . . . . . . . 1-11-3 STOCK SELECTOR, MODEL SSC . . . . . . . . . . 1-32-1 SAMPLE OF OPERATOR CHECK LIST . . . . . . 2-32-2 OPERATOR’S CONTROLS . . . . . . . . . . . . . . . . 2-42-3 FULL FEATURE DISPLAY . . . . . . . . . . . . . . . . . 2-52-4 RED ACTUATING ARM . . . . . . . . . . . . . . . . . . . 2-83-1 DASH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 3-33-2 THROTTLE CONTROL. . . . . . . . . . . . . . . . . . . . 3-33-3 LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . 3-44-1 POWER STEERING UNIT CONNECTOR . . . . . 4-34-2 POWERPAK CONTROLLER MODEL NUMBER 4-54-3 CONNECTOR A WIRING . . . . . . . . . . . . . . . . . . 4-64-4 CONNECTOR B WIRING . . . . . . . . . . . . . . . . . . 4-64-5 CONNECTOR C WIRING . . . . . . . . . . . . . . . . . . 4-64-6 SERIES TRACTION REGEN . . . . . . . . . . . . . . . 4-74-7 POWERPAK CONTROLLER MODEL NUMBER 4-84-8 CALIBRATOR FLOW CHART . . . . . . . . . . . . . . 4-84-9 WIRING DIAGRAM (SHEET 1). . . . . . . . . . . . . 4-105-1 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . 5-15-2 POWER STEERING, DRIVE AND BRAKE . . . . 5-25-3 CHASSIS MOUNTED ELECTRICAL PARTS . . . 5-35-4 STEERING ADJUSTMENT. . . . . . . . . . . . . . . . . 5-56-1 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16-2 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27-1 POWER STEERING, DRIVE AND BRAKE . . . . 7-27-2 LOAD WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38-1 LIFT CARRIAGE ASSEMBLY. . . . . . . . . . . . . . . 8-18-2 INNER MAST AND RAM HEAD . . . . . . . . . . . . . 8-39-1 HYDRAULIC SCHEMATIC DIAGRAM . . . . . . . . 9-19-2 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 9-39-3 THROTTLE CONTROL. . . . . . . . . . . . . . . . . . . . 9-49-4 DASH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 9-59-5 THROTTLE VALVE ASSEMBLY . . . . . . . . . . . . 9-69-6 PUMP AND MOTOR ASSEMBLY . . . . . . . . . . . 9-79-7 LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

10-1 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2 CHASSIS MOUNTED ELECTRICAL PARTS . . 10-310-3 EPD PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-310-4 ELECTRICAL CONTROL PANEL . . . . . . . . . . . 10-410-5 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . 10-511-1 SIDE GUIDE ROLLER (STEEL) . . . . . . . . . . . . 11-111-2 SIDE GUIDE ROLLER (POLYURETHANE) . . . 11-111-3 OPERATOR SAFETY HARNESS. . . . . . . . . . . 11-211-4 OPERATOR SAFETY BELT . . . . . . . . . . . . . . . 11-211-5 PALLET CLAMP . . . . . . . . . . . . . . . . . . . . . . . . 11-311-6 SLIP ON PLATFORM . . . . . . . . . . . . . . . . . . . . 11-412-1 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . 12-212-2 STEERING COLUMN REWORK . . . . . . . . . . . 12-312-3 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-412-4 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . 12-612-5 POWER STEERING, DRIVE AND BRAKE. . . . 12-812-6 BASE, FRAME AND PLATES. . . . . . . . . . . . . 12-1012-7 BATTERY ROLLOUT . . . . . . . . . . . . . . . . . . . 12-1212-8 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1312-9 LOAD WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . 12-1412-10 INNER MAST AND RAM HEAD . . . . . . . . . . . 12-1612-11 LIFT CARRIAGE ASSEMBLY. . . . . . . . . . . . . 12-1812-12 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . 12-2012-13 THROTTLE CONTROL. . . . . . . . . . . . . . . . . . 12-2212-14 THROTTLE VALVE ASSEMBLY. . . . . . . . . . . 12-2312-15 LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 12-2412-16 CHASSIS MOUNTED ELECTRICAL PARTS . 12-2612-17 HYDRAULIC PUMP AND MOTOR

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2812-18 24V HYDRAULIC PUMP MOTOR

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2912-19 DRIVE MOTOR ASSEMBLY. . . . . . . . . . . . . . 12-3012-20 ELECTRICAL CONTROL PANEL . . . . . . . . . . 12-3112-21 EPD PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3212-22 FLASHING RED LIGHT . . . . . . . . . . . . . . . . . 12-3312-23 WARNING LIGHT STAND . . . . . . . . . . . . . . . 12-3312-24 OPTIONAL LIFT LIMIT . . . . . . . . . . . . . . . . . . 12-34

ii 901270

LIST OF ILLUSTRATIONS - Continued

Figure Page Figure Page

12-25 OPTIONAL TYPE YC BATTERY & CHANGER CONNECTORS . . . . . . . . . . . . . . 12-35

12-26 OPTIONAL TYPE EC BATTERY & CHANGER CONNECTORS . . . . . . . . . . . . . . 12-36

12-27 OPTIONAL TYPE N BATTERY & CHANGER CONNECTORS . . . . . . . . . . . . . . 12-37

12-28 OPTIONAL TRAVEL CUTOUT . . . . . . . . . . . . 12-38

12-29 PALLET CLAMP . . . . . . . . . . . . . . . . . . . . . . 12-4012-30 OPTIONAL SLIP ON PLATFORM . . . . . . . . . 12-4212-31 SAFETY HARNESS & LANYARD . . . . . . . . . 12-4312-32 SAFETY BELT . . . . . . . . . . . . . . . . . . . . . . . . 12-4312-33 SIDE GUIDE ROLLER (STEEL) . . . . . . . . . . 12-4412-34 SIDE GUIDE ROLLER (POLYURETHANE) . 12-44

LIST OF TABLES

Table Page Table Page

2-1 OPERATOR CHECKS . . . . . . . . . . . . . . . . . . . . 2-22-2 DIAGNOSTIC/STATUS TEXT MESSAGES . . . . 2-63-1 MONTHLY AND QUARTERLY INSPECTION

AND SERVICE CHART. . . . . . . . . . . . . . . . . . . . 3-13-2 RECOMMENDED LUBRICANTS . . . . . . . . . . . . 3-23-3 LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . 3-44-1 TROUBLESHOOTING CHART . . . . . . . . . . . . . . 4-1

4-2 PIN ASSIGNMENTS . . . . . . . . . . . . . . . . . . . . . . 4-44-3 CONNECTOR A PIN OUTS . . . . . . . . . . . . . . . . 4-54-4 CONNECTOR B PIN OUTS . . . . . . . . . . . . . . . . 4-54-5 CONNECTOR C PIN OUTS . . . . . . . . . . . . . . . . 4-54-6 USER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . 4-84-7 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

901270 iii

PREPARATION FOR USE

Upon receipt, visually inspect stock selector and bat-tery charger. If any damage is found, report it to thecarrier and to your Big Joe dealer immediately.

Remove cardboard banded to forks. Check stockselector and battery charger for scratches and dents.Check to make sure that the lift chains are secure.Inspect for oil leaks and loose wiring connections.Make certain that all assessors and attachments thatwere ordered are supplied.

Provisions have been made to prevent the lift carriagefrom being moved from a predetermined position dur-ing transit. These include the following:

1. A lift carriage locking device (see Figure A) hasbeen installed at the top of the inner mast and theram head.

Figure A Supporting Clamp

2. The positive lead of the lift pump has been dis-connected.

3. The lift carriage is banded down to the straddlelegs.

To place the lift carriage in operation, perform the fol-lowing steps:

1. Cut banding which holds the lift carriage to strad-dles.

2. Connect positive lead to pump motor (inside con-trol cabinet).

3. Raise lift carriage so that inner mast protrudesfrom the mast section sufficiently to remove yel-low shipping clamp (see Figure A).

4. Remove 3/8 inch bolt and yellow shipping clampfrom the inner mast and raise head. The lift car-riage is now ready for normal operation.

Before the stock selector is moved, the battery mustbe checked, recharged if necessary, and connected. Ifthe stock selector was ordered without a battery, afreshly charged battery of adequate size and properweight must be installed. Refer to “Battery Care” inSECTION 3 for battery checking instructions.

CAUTION: The battery is extremely heavy (Approxi-mately 800 pounds). Do not attemptremoval or installation with out powerassistance.

Refer to SECTION 2 for operating instructions and testthe following controls:

SPEED Control Lever

Brake Pedal

LIFT Control

If you do not obtain the proper results, of it improperoperation occurs, refer to troubleshooting and repair inSECTION 3. The adjustment and repair proceduresare supplement with illustration.

R3000

Iv 901270

SECTION 1DESCRIPTION

1-1. INTRODUCTION.

This publication describes the SSC series of counter-balanced stock selectors Serial Number 379414 andhigher, manufactured by Big Joe Manufacturing Com-pany, Des Planes, Illinois 60018. SSC (Figure 1-3) isdescribed in described in detail, with operating instruc-tions, planned maintenance instructions, lubricationprocedures, corrective maintenance procedures and acomplete parts list with parts location illustrations.

Users shall comply with all requirements indicated inapplicable OSHA Standards and current edition ofA.N.S.I B56.1 Part II. By following these recommenda-tions contained in this manual, you will receive manyyears of dependable service from your Big Joe StockSelector.

The model number will be found on the name plate(Figure 1-1) along with the serial number, lifting capac-ity, and load center. Figure 1-3 Shows the serial num-ber locations, if the name plate is missing or illegible.

Figure 1-1 Name Plate

1-2. GENERAL DESCRIPTION.

The self-propelled SSC lifts and transports the opera-tor (on the platform portions of the lift carriage) and thepayload (on forks or optional payload platform). Thispermits efficient selection and moving of materials inany area or at any level of the warehouse or store-room. The design permits one man to perform all oper-ations of selecting the stock, driving the truck, andreplacing the stock at the designated place. The bat-tery-powered truck is quiet and without exhaust fumes,allowing operation in closed areas without special pro-visions for ventilation.

The SSC-30 is capable of lifting a 3000-pound pay-load. The lift carriage rises at a fixed speed but thelowering speed is infinitely variable. A manual opera-tor-controlled valve regulates the lowering speed.

The reversible DC motor propels the truck in forwardor reverse direction throughout the available speedrange. The SSC can be driven with the lift carriageraised or lowered; however the speed is restrictedwhen the lift carriage is raised Above 24 inches.

A power steering makes the truck highly maneuver-able. A braking method may be employed by the oper-ator to stop the SSC.

SSC lift capacities generally are established for a 24-inch load center. The center of gravity of a capacityload can not exceed the load center specified on thename plate for your truck, as configured at time ofdelivery from factory. See Figure 1-2 for load centerlocation. Additional lifting equipment such as remov-able payload platforms and special attachments mayalter the load center, and consequently lower the ratedlifting capacity of the truck.

Figure 1-2 Load Center of Gravity

R6423

BIG JOE MANUFACTURING COMPANYBIG JOE MANUFACTURING COMPANY

WISCONSIN DELLS, WISCONSIN 53965WISCONSIN DELLS, WISCONSIN 53965

AUSTRALIAN PATENT NO. 537,987AUSTRALIAN PATENT NO. 537,987

U.S. PATENT NO. 4,444,284U.S. PATENT NO. 4,444,284

REQUIREMENTS OF ANSI B56.1REQUIREMENTS OF ANSI B56.1

AND OSHA STANDARDSAND OSHA STANDARDS

COMPLIES WITH THE APPLICABLECOMPLIES WITH THE APPLICABLE

MAX CAP LB/MAX CAP LB/ LOAD CTR IN/LOAD CTR IN/ LIFT HGT IN/LIFT HGT IN/

LOAD CTR IN/LOAD CTR IN/ LIFT HGT IN/LIFT HGT IN/ALT CAP LB/ALT CAP LB/

BATTERY MIN WT LB/BATTERY MIN WT LB/TRUCK WT LESS BATTERY LB/TRUCK WT LESS BATTERY LB/

BATTERY MAX WT LB/BATTERY MAX WT LB/TRUCK WT WITH BATTERY LB/TRUCK WT WITH BATTERY LB/

OEM TYPE ATTACHMENTOEM TYPE ATTACHMENT

MAX CAP LB/MAX CAP LB/ LOAD CTR IN/LOAD CTR IN/ LIFT HGT IN/LIFT HGT IN/

BATTERY TYPEBATTERY TYPETRUCK TYPETRUCK TYPE CERTIFIED VOLTAGE

MODEL NO.MODEL NO. SERIAL NO.SERIAL NO.

ATTACHMENT SERIAL NO.ATTACHMENT SERIAL NO.COMB SERVICE WT LESS BATTERY LB/COMB SERVICE WT LESS BATTERY LB/

KG MM MM

MM MMKG

KGKG

KGKG

KG MM MM

KG

R6317

901270 1-1

1-2.1. Weight

CAUTION: Use of a battery weighting less than theweight specified on the truck name platewill affect truck stability.

Weight distribution of a counterbalanced truck is criti-cal; therefore the weight of the battery is very impor-tant. A battery of less than minimum weight (see nameplate) will adversely affect stability, particularly with thelift carriage raised. The battery compartment is fabri-cated for the battery purchased with the truck. Areplacement battery must be of proper size and weightfor your SSC. The battery spacer must be placedbetween the battery and the mast when a spacer isrequired.

1-3. SAFETY FEATURES

The SSC is designed with many standard safety fea-tures. Some of the convenience options also havesafety applications. The following safety features arestandard.

1. Dead-man brake to prevent accidental runaway.

2. Automatic high speed limit switch to restrict speedwhen lift carriage is raised above 24 inches.

3. Key-operated power switch to prevent operationby unauthorized personnel.

4. Handrails and/or safety chains on the platform.

5. Operator safety harness and lanyard

6. Shatterproof plexiglass screen on the front of theplatform between operator and moving mastmembers.

7. Flashing red warning light

8. Separately fused control circuits and power cir-cuits.

9. Emergency power disconnect system.

10. Horn.

11. Overhead guard.

12. Full feature display.

13. Hangup feature to stop descending cylinder andmast if lift carriage hangs up on an obstruction.

1-4. OPTIONS

If your Big Joe stock selector has optional equipmentor features not covered by this technical manual,check with your Big Joe dealer for applicable supple-ments or addenda.

1-5. SAFETY SYMBOLS.

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

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

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

1-2 901270

Figure 1-3 Stock Selector, Model SSC

R6425

901270 1-3

NOTES

1-4 901270

SECTION 2OPERATION

2-1. GENERAL.

This section gives detailed operating instructions forcounterbalanced stock selector. The various functionalsystems are first explained to provide a broad under-standing of how the truck operates, followed by step-by-step operating procedures. Routine precautionsare included to guarantee safe operation.

2-2. OPERATING PRECAUTIONS.

WARNING: Improper operation of the stock selectorlift truck may result in operator injury, orload and/or lift truck damage. Observethe following precautions when operatingthe stock selector truck.

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

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

3. Overloading will result in damage to the hydraulicsystem and lift mechanism. Do not exceed therated lifting capacity.

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

5. Center and carry the load as far back toward thelift carriage as possible. Do not pick up loads ontips of the forks. The center-of-gravity of the loadmust not exceed the load center listed on thename plate. See Figure 1-2 for load center limita-tions.

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

7. Always lower the load when traveling to increasevehicle stability.

8. When stacking pallets in racks, it is necessary tomove the load in the raised position. Move slowlyand use care when turning at a right angle.

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

10. Apply the mechanical brake gently except in caseof emergency.

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

901270 2-1

2-3. BEFORE OPERATION.

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

Figure 2-1 shows a sample format for a OperatorChecklist, which can be modified as necessary to fityour operation.

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

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

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

Table 2-1 Operator Checks

ITEM PROCEDURETransmission and hydraulic systems.

Check for signs of fluid leakage.

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

Chains, cables and hoses

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

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

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

Horn Check that horn sounds when operated.

Steering Check for smooth operation and automatic centering.

Travel controls Check that speed control lever operates in all speed ranges in forward and reverse.

ITEM PROCEDUREWheels Check drive wheel for cracks or

damage. Move truck to check load wheels for freedom of rota-tion.

Hydraulic con-trols

Check operation of lift and lower to their maximum positions.

Brakes Check that brakes release when the brake pedal is depressed.

Deadman/Park-ing brake

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

Battery discon-nect

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

Battery charge Check the battery condition as shown on the Full Feature Dis-play.

High speed limitswitch

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

2-2 901270

Figure 2-1 Sample of Operator Check List

R6426

Electric TruckDaily Operator Check-Off List

Date

Big Joe Manufacturing Company

Operator

Truck No. Model No.

Dept.

Check

Tires

Load Wheels

Horn

Lift Lower Controls

Need MaintenanceO.K. ( )

Shift

Hour Meter

Reading Drive Hoist

Forward & Reverse Controls

Steering

Electrical Brake

Hydraulic Leaks, Cylinders,

Valves, Hoses, Etc.

901270 2-3

2-4. INSTRUMENTS AND CONTROLS

Refer to Figure 2-2.

Brake Pedal (1): Used to release the electrical brakewhen depressed and engage the brake whenreleased.

Steering Wheel (2): Used to control the direction oftravel.

Full Feature Display (3): Used monitor various func-tions. See 2-4.1.

Manual Lowering Valve Lever (4): Used to manuallylower the operator’s platform and forks in case of apower loss.

Power ON Indicator Light (5): Used to indicatepower is present for controls.

Key Switch (6): Used to prevent unauthorized per-sonnel from operating the lift truck.

Horn (7): Used to sound the horn.

Lift/Lower Switch (8): Used to raise and lower theoperator’s platform and forks.

Speed Control Lever (9): Used to control the direc-tion and speed of the truck. This lever is also used forplug braking by moving it to the opposite direction oftravel.

Emergency Power Disconnect Switch (10): Used todisengage the emergency power disconnect locatedinside the base and frame compartment, disconnect-ing all power to the truck in case of an emergency.

Lift Limit Override Pushbutton (11): Used to over-ride the lift limit switch allowing additional lifting of theoperator’s platform and forks.

Pallet Clamp Release Lever (13): Used to secureand release the pallet on the forks.

Figure 2-2 Operator’s Controls

R6424

1

2

3

4

56

7

8

9

10

1. BRAKE PEDAL2. STEERING WHEEL3. FULL FEATURE DISPLAY4. MANUAL LOWERING VALVE5. POWER ON INDICATOR LIGHT6. KEY SWITCH7. HORN8. LIFT/LOWER SWITCH9. SPEED CONTROL LEVER10.EMERGENCY POWER DISCONNECT11. LIFT LIMIT OVERRIDE PUSHBUTTON12. PALLET CLAMP RELEASE LEVER

12

11

2-4 901270

2-4.1. Full Feature Display

The unit consists of a custom graphic LCD displayhoused in a rectangular plastic case. The displayincorporates a 10 segment BDI (Battery DischargeIndicator), a 6 digit hours counter and a 14 characterarea for diagnostic and status messages. The displayhas 11 warning symbols which can be lit by controller(via the CANbus) or by 8 active low switch inputs.When there are no diagnostic messages the top line ofthe message area it for the hourmeter along with thehour glass indicator.

2-4.1.1.Full Feature Display Features:

• Full-custom LCD with LED backlight.

• Readily understandable display format consisting ofnumbers, text and segments.

• 5 segment steering indicator

• 10 segment BDI indicator, with low charge warningand cutout warnings.

• 14 character text based diagnostic/status display.

• 6 digit hours based diagnostic/status display.

• Capable of counting up to 99999.9 hours. Equatesto 34 years @ 8 hour shift per day.

• Keyswitch, Traction and Pump hours count can beshown, identified as K.T.P.

• Hours count retained in display in the event of a con-troller or logic replacement.

• Speed indication (indicator #2), can be repro-grammed via calibrator.

• Text status area can show one of a selection of sys-tem status readings.

2-4.1.2.Diagnostic/Status Text Messages

The controller can transmit text messages for diagnos-tic and status indication. These messages overwritethe hours counter until the fault condition has cleared.Some messages may be displayed with one or moresymbols. The following table shows the fault messageand symbols displayed for each fault condition.

Figure 2-3 Full Feature Display

R6427

901270 2-5

Table 2-2 Diagnostic/Status Text Messages

MESSAGE SYMBOLS FAULT DESCRIPTION

SPEEDPROBE

Speed limit feature enabled & wire off.

ACCELFAULT

Accelerator wire off. Recycle FS1 and Direction.

ACCELFAULT

Accelerator pedal pressed at power up, or wire off.Recycle FS1 and Direction.

CONTACTFAULT

Contactor has bad contact or didn’t close, motor o/c.Recycle FS1 and Dir.

CONTACTFAULT

Contactor didn’t open or is welded. Recycle FS1 andDirection Switch.

SEQFAULT

Direction or FS switch at power up. Recycle DirectionFS1 or both.

2 DIRFAULT

Two directions selected together. Recycle bothDirections and FS1.

BATTERYLOW

Battery < Low battery personality. Recycle FS1 orDirection switch.

BATTERYHIGH

Battery > High battery personality. Recycle FS1 orDirection switch.

PERSERROR

Personalities out of range at power up.

CRCERROR

One or more personalities have been corrupted.

2-6 901270

2-5. OPERATION

2-5.1. Driving and Stopping Procedures

Proceed as follows to start and stop the stock selector.Refer to Figure 2-2.

1. Step on the platform facing the control consoleand turn the key switch (6) on.

2. Step on the brake pedal (1) to release the brakeand to activate the electrical controls.

3. Note the position of the drive wheel as indicatedby the steering indicator on the Full Feature Dis-play (3).

4. Pace one hand on the steering wheel (2) and beprepared to steer the stock selector in the desireddirection.

5. To move forward, slowly push the SPEED controllever (10) towards FORWARD. The stock selectorwill creep forward. Pushing the lever farthercauses the speed to increase.

6. To stop, slowly move the speed control lever (9) tothe opposite direction and then lift foot from thebrake pedal.

NOTE: The stock selector direction may be reversedwhile moving. The control will cycle the motorto a stop and a reverse in a timed sequencewithout danger to the equipment. Exercisecaution when doing so, especially when trav-elling at maximum speed.

7. To stop rapidly when an emergency exists, lift footfrom brake pedal quickly.

WARNING: Except in an emergency, do not stopsuddenly.

8. To move in reverse, step on the brake pedal andslowly pull the SPEED control lever (10) towardREVERSE. Pulling farther increases the speed.

2-5.2. Braking

Following are the various methods for stopping thevehicle.

• While traveling forward, move the SPEED controllever (9, Figure 2-2) from FORWARD to REVERSEor, while traveling backward, move the SPEED con-trol lever (9) for REVERSE to FORWARD. This canalso be done with resistor speed controlled stockselectors FOR EMEERGENCIES.

• Release the SPEED control lever (9) and allow thevehicle to coast to a stop.

• Release the SPEED control lever (9) and lift yourfoot from the brake pedal (1).

2-5.3. Operating Lift

Proceed as follows to raise and lower the lift carriage.Refer to Figure 2-2.

1. Step onto the platform and stand near the controlstation.

NOTE: It is not necessary to release the brake. Formaximum safety, leave the brake on.

2. Turn on the key switch (6).

Table 2-2 Diagnostic/Status Text Messages - ContinuedMESSAGE SYMBOLS FAULT DESCRIPTION

COILFAIL

A contactor coil s/c or miswired. Recycle Keyswitch.

MOSFETFAIL

Bypass contactor s/c or MOSFET s/c. Recycle FS1 ofDirection

FAIL If any of these message are displayed then the controller has failed one of its internal power up checks.

901270 2-7

WARNING: Check the space above your head andabove the entire lift carriage to be surethat the platform mast or load will not hitany obstructions while being raised.

3. To raise the lift carriage, activate the lift/lowerswitch (8, Figure 2-2). This is a three-positionswitch, forward position lowering the lift carriage,rear position raising the lift carriage, and the cen-ter position stopping the lifting/lowering process.

NOTE: The lift carriage will raise as long as the lift/lower switch is in the forward position, or untilthe lift carriage reaches maximum height.

4. Return the lift/lower switch to center positionwhen the lift carriage reaches the desired height.

5. To lower the lift carriage with the speed controllever (9), position the lift/lower switch (8) in theforward position.

6. When the lift carriage reaches the desired level,return the lift/lower switch to the center position.

NOTE: In the event of electrical power loss, theoperator can lower the lift carriage using themanual lowering valve lever (4). Slowly pushthe lowering lever forward toward DOWN.Return lever to neutral position when lift car-riage reaches desired level.

The the lift carriage can also be lower fromthe ground by opening the cabinet door andpushing the red actuating arm (Figure 2-4).

2-5.4. Fork Loading

1. Before moving stock selector, lower the lift car-riage

NOTE: Lowering the lift carriage lowers the stockselector center of gravity, which in turnincreases the stability when traveling.

2. Move the stock selector to the pick-up area.

3. Raise forks to the desired height for entry into thepallet or skid.

4. Move into position, so that the forks are within thepallet or skid and the load is centered over theforks.

5. Move the stock selector to place load againstedge of operator deck; then raise forks to lift thepallet.

Figure 2-4 Red Actuating Arm

CAUTION: Avoid spilling the load. Move slowly anduse extra care when turning.

6. Slowly move the stock selector to free load fromits rack; then when load is clear of it rack, lowerthe load leaving enough floor clearance tomaneuver.

7. Drive carefully to area where the load is to beplaced.

8. Move stock selector to align load with its newposition.

9. Raise loaded forks to the height desired andslowly drive into position.

CAUTION: The load must rest squarely on its rackwhen it is lowered into position.

10. When the load is in position, lower the forks untilthe pallet rests on its rack and the forks are free.

11. Move backward slowly, making sure that theeforks do not catch on the pallet and lower theforks when they are clear.

R6428

2-8 901270

2-5.5. Parking

1. To park, lift your foot from the brake pedal. Thisde-energizes the electrical circuits and engagesthe brake.

2. Turn off the key switch.

3. When finished moving loads, drive stock selectorto it maintenance or storage area. Charge batteryas required, see SECTION 3.

2-5.6. Emergency Power Disconnect (Figure 2-2)

In an emergency, all power can be turned off at onceby depressing the EMERGENCY POWER DISCON-

NECT (EPD) PUSHBUTTON SWITCH (10). Once thiscircuit is actuated, none of the electrical controls willoperate until the circuit is reset, but the lift carriage canbe lowered.

To make the vehicle operable, the emergency powerdisconnect must be reset. The emergency power dis-connect reset switch (12, Figure 12-16) is located onthe side of the chassis electrical compartment.

2-5.7. Moving a Disabled Truck

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

901270 2-9

NOTES

2-10 901270

SECTION 3PLANNED MAINTENANCE

3-1. GENERAL.

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

3-2. PERIODIC CHECKS.

Table 3-1 is an inspection and service chart based onnormal usage of equipment eight hours per day fivedays per week. If the lift truck is used in excess of fortyhours per week, the frequency of inspection and ser-

vice should be increase accordingly. These proce-dures must be performed by a qualified servicetechnician or your Big Joe service representative.

3-3. BATTERY CARE.

3-3.1. General.

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

Table 3-1 Monthly and Quarterly Inspection and Service Chart

VISUAL CHECKSINTERVAL INSPECTION OR SERVICE

Monthly Check drive motor for proper operationMonthly Check pump motor for proper operationMonthly Check brake for proper operationMonthly Check transmission for oil leaksMonthly Check hydraulic system for leaksMonthly Check hydraulic oil levelMonthly Check load wheels for wearMonthly Check drive wheel for wearMonthly Inspect wiring for loose connections and damaged insulationMonthly Inspect contactor tips for excessive pitting and wearMonthly Check lift chain tension, lubrication & operation (See paragraph 3-5.)Monthly Lubricate unit (See Table 3-3)Quarterly Check lift cylinder for leakageSemi-annually Replace hydraulic filter assemblySemi-annually Inspect for chain wear (See paragraph 8-3.)

901270 3-1

3-3.2. Battery Servicing.

Refer to Document 245 for battery safety and mainte-nance.

Perform the following procedures at end of each day:

1. Obtain a battery hydrometer.

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

2. Open the battery cover and remove the vent caps.

3. Use the hydrometer to check specific gravity ofeach cell.

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

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

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

4. Charge battery as necessary.

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

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

3-4. LUBRICATION.

Refer to Table 3-2 for the recommended types ofgrease and oil. Table 3-3 in conjunction with Figure 3-3identifies the items requiring lubrication.

Table 3-2 Recommended Lubricants(See Table 3-3 for Application)

3-4.1. Hydraulic System Capacity

The hydraulic system capacity depends on the liftheight as follows:

106” 2 gallons130” 2 gallons154” 3 gallons168” 3 gallons190” 3 gallons

Use Big Joe Hydraulic Oil part number 900855.

3-5. LIFT CHAIN MAINTENANCE.

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

No. 1 Transmission oil—EP SAE 80W-90 (in temperatures below 32°F use 10W-30)

Transmission oil capacity is 2.5L.

No. 2 Grease—Lithium base, general purpose.

No. 3 Hydraulic oil-Heavy duty with a viscosity of 150 SUS (in temperatures below 32°F use 100 SUS) foam suppressing agent and rust and oxidation inhibitors.

Big Joe Part No.900855 (1 gallon)900893 (1 quart)

No. 4 SAE 30 or 40 Engine lubricating oil

3-2 901270

3-6. THROTTLE CONTROL LUBRICATION

The following procedure should be followed to insureproper lubrication of the throttle control lever. SiliconGrease, Big Joe Part Number 055753, must beapplied to the shaft of the throttle control lever. Accessto this point requires the removal of the steering wheeland dash cover plate.

1. Remove the four screws (3, Figure 3-1) securingthe dash cover plate (4).

2. Move the dash cover plate (4) out and disconnectharness (2) from steering wheel and columnassembly (1).

3. Remove dash cover plate (4) with steering wheeland column assembly (1).

Figure 3-1 Dash Removal

4. Check for wear on the pin of the bracket, Figure3-2, and the lever hole in the lever. If noticeablyworn or hole is elongated, replace with new parts(refer to Figure 12-13).

5. Liberally lubricate the bracket pin using SiliconGrease, Big Joe Part Number 055753 or equiva-lent.

6. If new parts have been incorporated, perform theThrottle Vale Adjustment Procedure provided inparagraph 9-6.

Figure 3-2 Throttle Control

7. Move the dash cover plate (4) into position andreconnect harness (2) to steering wheel and col-umn assembly (1).

8. Securing the dash cover plate (4) with the fourscrews (3).

12

3

4

R6428 R5878

901270 3-3

Figure 3-3 Lubrication Diagram

Table 3-3 Lubrication Chart

FIG 3-3INDEX

NO.

LOCATION METHOD OF APPLICATION

TYPE (Table 3-3)

APPLICATION OF

LUBRICANT1 Transmission Can No. 1 Fill to plug level.2 Hydraulic system Can No. 3 Fill, so oil shows full on dipstick

with lift carriage fully lowered.3 Mast and inner mast Brush No. 2 Full length of mast where rollers

touch4 All hinges Can No. 4 Oil sparingly.

R6429

3-4 901270

SECTION 4TROUBLESHOOTING

4-1. GENERAL

Table 4-1 serves as a guide to determine possiblecauses of trouble. The table is divided into five maincategories: Truck Dead: Trouble With Travel: TroubleWith Braking: Trouble With Lifting Or Lowering, and OilLeaks. Refer to electrical wiring diagram (Figure 4-9)

as a supplement to the troubleshooting chart or whentracing an electrical circuit. Refer to paragraph 4-2. asa supplement to troubleshooting the power steeringregulator. Refer to paragraph 4-3. as a supplement totroubleshooting the Powerpak Controller.

Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

TRUCK DEAD

Truck will not run nor will lift sys-tem operate.

a. 300 Amp fuse blown. Check fuse and replace if defec-tive.

b. Battery dead or disconnected. Check battery quick-disconnect plug.

Check battery.

c. Keyswitch defective. Bypass keyswitch to determine if it is malfunctioning. Replace if required.

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

e. Emergency power disconnect circuit off.

Check and reset as required.

TROUBLE WITH TRAVEL

Platform operates, but drive motor will not run. Contactors do not operate

a. Check all wiring. A loose con-nection may be the cause of malfunction.

Tighten all loose connections before further troubleshooting.

b. Open line to switch control. No positive voltage applied to accelerator switch.

Check brake switch, and contacts of all switches in the circuit for open condition. Repair or replace.

Drive motor operates in only one direction. Platform operates nor-mally.

Forward or Reverse contactor does not operate.

Check continuity of coils, and con-tacts and switches in speed con-trol. Replace as required.

Truck will not travel at high speed with load lowered.

High speed switch out of adjust-ment or defective.

Check operation of high speed limit switch. Adjust or replace switch as necessary.

TROUBLE WITH TRAVEL

Truck runs forward and in reverse at slow speed. Will not run at higher speeds.

a. Defective joystick controller. Replace if defective.

b. High speed switch out of adjust-ment or defective.

Check operation of high speed limit switch. Adjust or replace switch as necessary.

901270 4-1

Table 4-1 Troubleshooting Chart - Continued


TROUBLE WITH TRAVEL - Continued

Truck runs at high speed only. Everything else is normal.

a. Defective joystick controller. Replace if defective.

b. Damaged PowerpaK controller. Replace if defective.

TROUBLE WITH LIFTING OR LOWERING

Platform does not lift to top. Oil level too low. Lower platform completely then add oil until oil reaches full mark on dipstick.

Lowering valve does not return to neutral.

a. Foreign particles. Clean system and valve.

b. Misalignment of valve linkage. Adjust as required.

Truck runs forward and in reverse, but platform does not rise.

Defective electrical system for operating pump motor.

Place hand against pump motor while assistant presses LIFT pushbutton. If motor runs, defect is in hydraulic system. If motor does not run, tighten electrical connections, then check LIFT pushbutton switch, the solenoid relays, and the pump motor. Repair or replace.

Truck runs and platform rises, but will not go down.

a. Defective throttle valve. Check throttle valve. Repair or replace as required.

b. Defect in hydraulic system. Look for obstruction in the hydrau-lic system. Repair as required.

c. Defective hangup valve. Replace.

Platform creeps downward under load when in raised position. Everything else is normal.

a. Leak in hydraulic system. Look for loose fittings on the hydraulic line. Check the check valve and pump for leakage back into the reservoir. Also check for overloading or defective relief valve in pump. Repair or replace as required.

b. Lowering valve out of adjust-ment.

Adjust valve as required.

Squealing sound from pump when platform is raised.

a. Oil level too low. Add oil to 1 in. of top when plat-form is completely lowered.

b. Dry channels in mast. Apply grease.

c. Defective bearing. Replace bearing.

d. Pinched suction line or plugged filter.

Check lines and replace filter as applicable.

4-2 901270

4-2. POWER STEERING REGULATOR

The power steering regulator (15, Figure 12-5) is afully digital AC regulator for drive motor (17).

The device has the following characteristics:

• small design

• 24V/60A

• 4-guadrant operation with completely continuos tran-sition between two guadrants

• operation as torque, speed or position regulator

• block commutation with hall sensor interface

• full torque at speed 0

• Analogue, RS232 and CAN bus interface

• the digital control makes possible a fault-tolerantoperation, that is errors are detected in time and reg-ulated if possible.

Figure 4-1 shows the power steering unit connectionsand Table 4-2 shows the pin assignments.

Figure 4-1 Power Steering Unit Connector

Table 4-1 Troubleshooting Chart - Continued


Platform does not lift, motor does not run.

a. Battery is dead or discon-nected.

Check and recharge if required.

b. Defective wiring. Check and repair as required.

c. Defect in electrical system for operating pump motor.

Check pump motor switch on lift control valve, as well as the sole-noid relays. Repair or replace.

OIL LEAKS

Oil sprays or flows from top of the lift cylinder.

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

Foaming oil in breather of hydrau-lic reservoir.

Leak in suction line between the pump and the reservoir.

Tighten fittings. Inspect line and replace if necessary.

Oil splashes out of breather when lowering platform.

Oil level to high. With platform completely lowered, check that oil is up to, but not over 1 inch from top of reservoir.

R6431

901270 4-3

Table 4-2 Pin Assignments

PIN NO. SYMBOL VALUE SPECIFICATION

Group“CAN”

2 CAN-HI +/-2VISODIS 11898

CAN-bus signals (differential)

10 CAN-LO

Group“analogue”

6 ENAB 0V/ Bat+protected againstreverse polarity

Supply Input from Battery for the internal logic,high=enabling power stage/motor

This could be the battery power to supply control logic. Drive is enabled when this pin is connected to Bat+

11 REF 0V/10V

CMOS-level

Digital logic input for reference sensor

PNP sensor: 100k pull down to GNDNPN sensor: 4,7Ω pull-up to 12V, possibility to use 100k pull-down

3 +12V_out +10V to +13Vmax. 10 mA

Auxiliary supply for ext. reference switch

12 GND_REF 0.7V/Ri = 5Ω Ground for reference sensor

5 A_IN0 0...5V/Ri = 60Ω

maximum inputvoltage: 5,5V

Analogue input 0 for e.g. analogue potentiometer,resolution: 12 Bit

13 A_IN1 0...5V/Ri = 60Ω

maximum inputvoltage: 5,5V

Analogue input 1 for e.g. analogue potentiometer,resolution: 12 Bit

4 +5V_out +5V/+5%max. 20mA

Supply for analogue pos. Sensor (for e.g. analogue potentiometer)(same port used for analogue monitor)

14 GND_out 0V/Ri = 5Ω Ground for analogue pos. Sensor

9 SER_IN 0V/10V Ri = 100kΩCMOS-Level

Modified RS232-Interface for PC, used for parameter-download and debugging in development phase!No real +/-10V RS232!1 SER_OUT 0V/10V Ro = 330kΩ

CMOS-Level

7,15 Bat- 0V 0V power return, reference potential for the whole electronic

8,16 Bat+ 24Vnormal

24V power supply for the motor

All inputs and outputs except Bat+ and Bat- are protected against incoming voltages of +70V and -3V.

4-4 901270

4-3. POWERPACK CONTROLLER

The Powerpak Controller is identified by model num-ber that shows controller variants as shown in Figure4-2. The model number of the controller used on theSSC is PP246M.

The PP246M Powerpak Controller has 3 connectors.Figure 4-3 and Table 4-3 show the wiring and pin outsfor the serial communications. Figure 4-4 and Table 4-4 show the wiring and pin outs for the vehicle connec-tions. Figure 4-5 and Table 4-5 show the wiring and pinouts for the contractor connections.

Figure 4-2 Powerpak Controller Model Number

Table 4-3 Connector A Pin Outs

Table 4-4 Connector B Pin Outs

Table 4-5 Connector C Pin Outs

1 + 10V52 0V3 N/C4 +10V55 CAN High6 CAN Low

P P x x x

1st digit - Controller Type - 1 = ----------2 = Traction3 = Pump4 = ----------5 = ----------6 = ----------7 = Reserved – (SEM)

2nd digit - Voltage Range - 2 = Reserved4 = 24V - 48V8 = 72V - 80V

– (24-36V)

3rd digit - Current Limit - 3 = 300A4 = 456 = 65

0A0A

Suffix - L = Low I/O, TractionM = Medium I/O, TractionH = High I/O, TractionP = Low I/O, PumpR6432

1 Key sw2 Fwd sw3 Rev sw4 FS1 sw5 Tiller sw6 See note7 See note8 See note9 See note10 Accel/F.Brake/Economy pot

/Over Temp 0V-5V11 Accel/F.Brake/Economy pot

/Over Temp 3V5-0V12 +12V o/p

NOTE: Can be configured to be any of the following: Speed1, Speed2, Speed3, Inch Rev, Pump, Power Steer Trigger, Handbrake, Footbrake, Sideload, Brushes Worn, Speed Encoder.

1 Cont. o/p2 Fwd Cont3 Rev Cont4 Regen/P.Steer Cont5 Bypass/F. Weak Cont6 P.Steer/F.Weak/Pump/Remote LED

901270 4-5

Figure 4-3 Connector A Wiring

Figure 4-4 Connector B Wiring

Figure 4-5 Connector C Wiring

R6433

R6434

R6435

4-6 901270

4-3.1. CAN (Controller Area Network) Overview

CAN is an acronym for Controller Area Network. It is abus system, meaning that it is a collection of intelligent“nodes” which are connected to the same physicalpiece of wire. If one node transmits something on thewire, all nodes will receive it (including the one doingthe transmitting).

CANbus was developed (in 1984) by Bosch, the Ger-man electronics manufacturer, for use in road vehi-cles. This aim of CANbus is to reduce vehicle wiring,as all electrical functions (such as lights, electric windows, ignition) share the same physical wire. Itsemphasis on reliable data transmission has made itpopular with manufactures of industrial equipment andmaterials handling vehicles.

The main applications for CAN communications areautomotive and industrial electronics where highspeed, noise immune serial communications arerequired to work reliably in high vibration and hightemperature environments.

SEVON’S CAN system is defined as CAN 2.0A (BasicCAN, error active) and is implemented using a PhilipsSemiconductor chip-set with an 80C250 transceiverchip. The PowerpaK CAN protocol sets the baud rateto be 100K bits per second.

CAN is extremely flexible and versatile, allowing multi-master operation in a serial communication networkwith an almost unlimited number of nodes. Data ratesof up to 1 Mbit/s are possible transmitting over dis-tances of up to 40 meters, with a very low probability ofundetected errors. CAN is basically a 2-wire twisted-pair differential system with 10V5 and 0V supply rails.Connections are made via a 6way Molex connector.

Presently the CAN bus is used to communicate withthe calibrator. It can be used to communicate with adashboard display and for remote control from a hostPC> Long term, communications with auxiliary control-lers and equipment will be possible.

E.g. Battery Chargers, Standalone Power Steer Con-trollers, Controller I/O expanders ...etc. At present it ispossible to connect up to 8 pieces of equipment ontothe CAN bus.

Figure 4-6 Series Traction Regen

R6436

901270 4-7

4-3.2. Diagnostics and Troubleshooting

A sophisticated Calibrator is used to make adjust-ments to the controller. The Calibrator is also used asa diagnostic tool displaying the status within the con-troller together with the condition of all the controller’sswitch and analogue inputs. To use the controller, dis-connect the harness from the full feature display fromconnector A of the Powerpak Controller and plug inthe Calibrator.

Figure 4-8 the flow through the various screens. Fig-ure 4-7 shows the display of the Calibrator. The leftand right arrows move between screens on the samelevel. The up and down arrows move between levelsand the + and - buttons increment or decrement theparameter by the amount indicated in the STEP col-umns of Table 4-6.

Figure 4-7 Powerpak Controller Model Number

Figure 4-8 Calibrator Flow Chart

Table 4-6 User Adjustments

R6447

R6446

CALIBRATOR REFERENCE

CAN NAME

DESCRIPTION MIN MAX STEP ACTUAL VALUE

1.1.2 1 Traction Accel Delay (s) 0.1 5.0 0.1 1.0

1.1.4 3 Traction Creep Speed (%) 0 25 1 7

1.1.6 5 Plug Neutral Braking (A) 0 810 10 10

1.1.12 12 Traction Max Speed (%) 0 100 1 100*

1.1.27 76 Traction Electric Brake Delay (s) 0 5.0 0.1 3.5

* Actual Value of 75 for 154” Lift Truck Only

4-8 901270

Table 4-7 Diagnostics

CALIBRATOR MESSAGE

FULL FEATURE DISPLAY

LED DESCRIPTION AND HOW TO CLEAR

CHECK

OK(lowest priority)

on Traction operational and OK. No action required.

Testing... on Only displayed briefly at power up.

No action required

Speed Probe SPEEDPROBE

6F Speed limit feature enabled & wire off.

Check probe connec-tions.

Accel. Fault ACCELFAULT

6F Accel. lever pressed at power up, or wire off. Recycle FS1 and Direction.

Check accel wiring. accel zero & full personalities.

Contactor o/c CONTACT FAULT

4F Contactor has bad contact or didn’t close, motor o/c. Recycle FS1 & Dir.

Check coil wiring, power wiring, motor o/c.

Contactor s/c CONTACT FAULT

4F Contactor didn’t open or is welded. Recycle FS1 and Direction switch.

Check for welded tips, particles in tips, wiring.

Sequence Fault SEQFAULT

2F Direction or FS1 switch at power up. Recycle Direc-tion FS1 or both.

Check Dir and FS1 in neutral and Dir/FS1 wiring.

2 Dir. Fault 2 DIRFAULT

2F Two directions selected together. Recycle both Directions and FS1.

Check direction switch wiring.

Battery High BATTERY HIGH

7F Battery > High battery per-sonality. Recycle FS1 or Direction switch.

Check correct bat-tery voltage. Loose or missing B+ to controller.

Battery Low BATTERYLOW

7F Battery < Low battery person-ality. Recycle FS1 or Direc-tion switch.

Check correct bat-tery voltage. Dis-charged battery.

Pers Error PERSERROR

1F Personalities out of range at power up.

Reset personalities out of range (shown as ----.-).

CRC error CRC ERROR

1F One or more personalties have been corrupted.

Check all personali-ties then recycle keyswitch.

Coil s/c COILFAIL

9F A contactor coil s/c or mis-wired. Recycle Keyswitch.

Check coil s/c, Drive connected directly to B+ve, wiring.

Mosfet s/c MOSFETFAIL

3F Bypass Contactor s/c or MOSFET s/c. Recycle FS1 or Direction.

Check A/P/B- power wiring, MOSFETs s/c.

Various internal con-troller power up messages (highest priority)

FAIL off If any of these message are displayed then the controller has failed on of its internal power up checks.

Check contact Sevcon.

901270 4-9

Figure 4-9 Wiring Diagram (Sheet 1)

R6430A

FWD REV

LIFT

NOTES:1. ALL CIRCUITS TO BE LABELED AS SHOWN IN A PERMANENT MANNER.2. OPTIONAL CIRCUITS SHOWN IN DASHED LINES.

E.P.D.

LOWER HORN

ACCEL

2

4

12

13

14

15

8

7

9

11

10

1

12

1

3

2

4

6

5

14

13

15

7

6

9

8

10

11

3

5

JOYSTICK

KEYSWITCH

INDICATOR

LIGHTSPEED LIMIT

FOOT PEDAL

STEERING WHEEL ASSEMBLY

DASHBOARD DISPLAY

1

2

3

6

8

11

12

1

2

3

5

6

7

8

11

12

13

14

15

4

9

10

4A

5A

1A

2A

6A

7A

8A

9A

10A

12A

4A

10

2A

6

10

12 13

9

101

3. F1 and F2 MOTOR CONNECTIONS CAN BE REVERSED TO CHANGE DIRECTION OF THE MOTOR.

RJ11 6 PIN

1

24

35

6

4

1 32 4

1 32 4

16 16

13

9

16

7Optional Speed Cutback

11A

3A

1A

3A

9A

7A

6A

8A

6A7A

8A

9A

5

14

1

1

14

NO

NC

10

8

9

6

7

5

1

3

4

2

1 27

38

49

510

611 12

1

3

2

GROUND WIRETERMINAL STRIP

1 1

11

1

1

1 1

NO

1

1

1 1

1 10

10

10 10

9 9

1

8 4 5

11

2 3

65

1APOT.

3A

4A

2A

POTENTIOMETER

SHAFT

4-10 901270

Figure 4-9 Wiring Diagram (Sheet 2)

R6430B

+

-

BATTERY

+

-

PUMP &MOTOR ASSY

NEG

F2

A2

F1

A1

DRIVE MOTOR

15 AMP

300 AMP

40 AMP

FLASHINGRED LIGHT

HORN

CONNECTOR

-

+

BATTERY

NOTES:1. ALL CIRCUITS TO BE LABELED AS SHOWN IN A PERMANENT MANNER.2. OPTIONAL CIRCUITS SHOWN IN DASHED LINES.

E.P.D.

- +

ENGAGE

E.P.D. RELAY

CONTACTOR

ELECTRIC BRAKE

PST REFERENCE

POS

15

14

10

13

12

11

9

7

8

5

6

4

2

3

1

11

15

13

14

12

10

8

9

6

7

5

1

3

4

2

SOLENOID

LOWERING

8 7 6 5 4 3 2 1

16 15 14 13 12 11 10 9

SEVCON PST

FUSE

1

2

3

6

7

8

11

6A

7A

8A

9A

2A

9

3A

4A

1

2

3

5

6

7

8

11

12

13

14

15

4

9

10 10

14A

13

12

13A

4A

5A

1A

2A

6A

7A

8A

9A

10A

12A

1

45

10

10

3A4A

12

13

13A

13A

1A2A

9

9

9

9

4A

9

4A

14A

3. F1 and F2 MOTOR CONNECTIONS CAN BE REVERSED TO CHANGE DIRECTION OF THE MOTOR.

S

B-

R

B+

BLK

0V

CO

NN

EC

TO

R"A

"

+10V5 12

4

CAN HIGH

CAN LOW

A

P

35

6

12

73

84

95

10

611

12

SEVCON POWERPAK

1

1

10 C

ON

NE

CT

OR

"C"

61

27

43

85

9BL

R

YW

BN

GN

R(2)

W

CONTACTORPUMP

BN

R(2)

CONTACTORFORWARD

CONTACTOR

REVERSEBL

R(2)

GNR(2)

CONNECTOR CABLE

PWRSTEER

CONTACTORBYPASS

16

16

4

16

1A

11A

3A

13A

14A

14

NO

3

1

2

TX

RX

SERIALCOMMUNICATION

RX

TX

A B 71 4 3 9 6

NC NONC NO

199

199

9

20

21

22

22

22

22

23

23

23

23

9

23

SEVCON CONTACTOR PANEL ASSY

CALIBRATOR

0V

CONNECTOR "A"SERIAL TxD

+10V5

12

4

CAN HIGH

SERIAL RxD

CAN LOW

3

56

901270 4-11

NOTES

4-12 901270

SECTION 5STEERING SYSTEM MAINTENANCE

5-1. GENERAL.

The steering system is engineered to met the designrequirements that the steering wheel be on the mov-able lift carriage and the capable of steering the stockselector while the lift carriage is in any position.

All connections (cables and chains) between the liftcarriage and body of the stock selector must remaintaut while allowing for movement of the lift carriage.

When the steering wheel is turned, the potentiometerof steering column (7, Figure 5-1) sends a signal toregulator (16, Figure 5-2) to drive the pinion gear ontransmission (7). The power steering reference switch(31) rides on cam (6) to prevent oversteering. A signalis also sent to the full feature display (3, Figure 5-1) toindicate drive wheel position.

5-2. STEERING ELECTRICAL CABLE.

5-2.1. Cable Tension Adjustment

1. Raise lift carriage to gain access to spring (29,Figure 5-1) mounted on the base of the stockselector.

2. Block lift carriage in raised position to preventaccidental lowering.

3. Loosen screws on strain relief (22) located on theframe and allow spring (29) to extend to itsrelaxed position.

4. Pull downward on electrical cable (21) from belowto eliminate slack, but do not pull taut.

5. Move strain relief (22) and spring (29) up to top ofbracket and, while compressing spring, tightenscrews on strain relief (22). When released,spring should pull cable taut.

Figure 5-1 Steering Wheel

R6404

1

23

4

56

71

1314

18

11920

21

22

2324

25

2627

28

28

2922

30

21

817

16

9

10

11 12

15

901270 5-1

6. If spring and strain relief do not move, cable waspulled too taut; if spring expands fully, slack wasnot removed. Repeat steps 3. through 5.

7. Remove blocks and lower lift carriage.

5-2.2. Upper Cable Replacement

Replace the cable (1, Figure 5-1) according to the fol-lowing procedure.

1. Move the truck to an area suitable for the repairoperation.

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

3. Turn of the key switch and disconnect the batteryconnector.

4. Remove the four screws (14) securing the dashcover plate (18).

5. Move the dash cover plate (18) out and discon-nect harness (1) from steering column (7).

6. Open cabinet doors located below the steeringwheel.

7. Remove screw (23), washer (24) and clamp (25)securing cable to the rear wall.

8. Disconnect cable (1) from full feature display (3).

9. Disconnect cable (1) from receptacle (19).

10. Install new cable in reverse of removal.

Figure 5-2 Power Steering, Drive and Brake

R6407

1

23

456

7

9

10

11

12

13

14

15

16

817

18

12

19

20

2122

23

24

25

26

27

28

2914

30

31

323334

3536

5-2 901270

5-2.3. Lower Cable Replacement



3. Raise the carriage to a height of three to six feetto be able to work under it.

4. Place strong steel automotive-type supportsunder the carriage approximately 24 inches outfrom the mast.

5. Lower the carriage onto the supports using the liftcontrols.

6. Check that the supports are secure and that thecarriage is lowered as far as it will go.


8. Remove the six screws (12, Figure 5-1) securingthe cover (11) and remove the hub.

9. Remove the three screws (10) securing the steer-ing wheel (9) and remove the steering wheel.


11. Disconnect cable (1) from receptacle (19).

12. Cut wires of cable (21) at receptacle (19) leavingsufficient wire to identify wire color code.

13. Loosen screws on strain relief (22) located on thecarriage and pull cable (21) out the bottom of thestrain relief and free of sheave (26).

14. Open cabinet door (7, Figure 12-6).

15. Disconnect cable (13, Figure 5-3) from harness(16).


17. Loosen screws on strain relief (22, Figure 5-1)located on the frame and pull the cable up and outof the bracket. Spring (29) and strain relief (22)will fall free.

18. Lift the cable free of its sheave on the ram head.

19. Lay old cable along the ground, measure it andcut new cable to this length, allowing severalextra inches to facilitate fitting and to account forlengths of wire cut off at connectors.

20. Route the length of the cable over its sheave onthe ram head and down through the bracket,spring (29) and strain relief (22). Do not securestrain relief at this time.

Figure 5-3 Chassis Mounted Electrical Parts

R6419

A

P

B+

B-

CB

A

R

S

FWD

CNTCR

REV CNTCR

A

APUMP CNTCTR

CNTCTR

BYPASS

VIEW A-A

123

4

121

3736

19

13

5

6

78

910

1112

3334

35

1

13

214

1516

17

18

19

2021

14

22

2928

27

26

30

27

31

32

3534

33BATT NEG TOCONTCTR PANEL

BATT POS TOCONTCTR PANEL

2324

25

901270 5-3

21. Route the cable into the frame.

22. Strip off a short piece of outer sheathing from bothends of the new cable.

23. Strip the end of each wire and crimp new contact(18, Figure 5-3) to wire ends.

NOTE: The color coding on the short piece of wirecut from the old cable can be used to insureproper connection of the new cable.

24. Connect the cable to receptacle (17) as follows:Match the color of the new cable wires with theshort piece of wire cut from the old cable andinsert the wire contacts into the proper position ofthe new receptacle (17).

25. Connect the receptacle (17) to harness (16).

26. Route the cable around sheave (26, Figure 5-1)and up through relief (22).


28. Strip the end of the ends of each wire and crimpnew contact (20) to wire ends.



30. Connect the receptacle (19) to harness (1).

31. Secure the cable with strain relief (22).

32. Adjust the cable tension as described in para-graph 5-2.1.

33. Secure cabinet door (7, Figure 12-6) closed.

34. Close and secure the cabinet doors located belowthe steering wheel.

35. Install the steering wheel (9, Figure 5-1) andsecure with three screws (10).

36. Install cover (11) and secure with six screws (12).

5-3. STEERING WHEEL AND COLUMN.

5-3.1. Steering Wheel Column Removal




4. Remove the six screws (12, Figure 5-1) and hub(11).

5. Remove three screws (10) and steering wheel (9).

6. Remove the four screws (14) securing the dashcover plate (18).

7. Move the dash cover plate (18) out and discon-nect harness (1) from steering column (7).

8. Remove four nuts (5), lock washers (6), screws(15), tubes (13), and steering column (7) fromcover plate (18).

5-3.2. Steering Wheel Column Installation

1. Secure new steering column (7, Figure 5-1) tocover plate (18) with four screws (15), tubes (13),lock washers (6) and nuts (5).

2. Lift dash cover plate (18) into position and recon-nect harness (1) to steering column (7).

3. Secure plate (18) with four screws (14).

4. Adjust the steering centering as described inparagraph 5-3.3.

5-3.3. Steering Centering Adjustment


2. Be sure to stop with the drive wheel positioned ina straight line.

3. Turn off the key switch and disconnect the batteryconnector.

4. Remove the six screws (12, Figure 5-1) and cover(11).


6. Open cabinet door located below the steeringwheel.

7. With the cabinet door open, temporarily reinstallthe steering wheel with the three screws (9).

8. Partially turn the steering wheel (4, Figure 5-4)and loosen set screw (3).

9. Release steering wheel (1) allowing gear (2) torotate on potentiometer (1).

10. Tighten set screw (3).

11. With the steering wheel centered, slowly drive thetruck and check for straight operation.

12. If necessary, repeat steps 8. through 11.

5-4 901270

Figure 5-4 Steering Adjustment

5-4. STEERING REGULATOR

5-4.1. Removal




4. Remove access panel (1).

5. Disconnect the harness from the top of regulator(16, Figure 5-2).

6. Remove four screws (15), four lock washers (14)and remove regulator (16) and adapter plate (13).

7. Remove nut (17) and pinion (8) from regulator(16).

5-4.2. Installation

1. Install pinion (8, Figure 5-2) on regulator (16) andsecure with nut (17).

2. Position adapter plate (13) and regulator (16) onbracket (9).

3. Secure regulator with four screws (15) and fourlock washers (14).

4. Reconnect the harness to the top of regulator(16).

5. Secure cabinet door (7, Figure 12-6) closed andreinstall access panel (1).

5-5. STEERING REFERENCE SWITCH

5-5.1. Removal




4. Remove access panel (1).

5. Tag and disconnect the wires from referenceswitch (31, Figure 5-2).

6. Remove two nuts (34), lock washers (33), wash-ers (32), screws (30), and switch (31).

5-5.2. Installation

1. Position switch (31, Figure 5-2) on the mountingbracket and install two screws (30), washers (32),lock washers (33) and nuts (34).

2. Adjust the switch so that it will be closed whenabove cam (6) and open when cam (6) is rotatedpast the switch.

3. Reconnect the wires to switch (31).

4. Secure cabinet door (7, Figure 12-6) closed andreinstall access panel (1)

R64451 2 3 4

901270 5-5

NOTES

5-6 901270

SECTION 6BRAKE SERVICING

6-1. BRAKE PEDAL SWITCH ADJUSTMENT

The brake pedal switch is mounted on the base of thebrake pedal.

Proceed as follows to check and adjust the switch:

1. With the brake pedal in the raised position, checkthat the flange of the brake pedal depresses thebutton of switch (6, Figure 6-1), but does nottouch the switch bushing.

2. If the flange does not depress the switch button,loosen the mounting screws of switch (6) and

move the switch toward the brake pedal flange,then tighten the mounting screws.

3. If the flange depresses he switch button and alsotouches the switch bushing, loosen the mountingscrews of switch (6) and move switch slightlyaway from the brake pedal flange, then tightenthe mounting screws.

4. Check activation of brake pedal switch by listen-ing for the audible click as the brake pedal isdepressed and again as the pedal is released.

Figure 6-1 Brake Pedal

12

34

5

6

67

8

9

10

11

12

R6404

901270 6-1

6-2. BRAKE ASSEMBLY REPLACEMENT

NOTE: There is no field service for brake assembly(25).

1. Block the wheels to prevent the stock selectorfrom rolling.



4. Tag and disconnect the wires from brake assem-bly (25, Figure 6-2).

5. Remove three screws (27) and remove disk (23)with brake assembly (25).

6. Remove four nuts (26) and screws (28) andremove disk (23) from brake assembly (25).

7. Install terminals (24) on new brake assembly (25).

8. Secure brake assembly (25) to disk (23) with fourscrews (28) and nuts (26).

9. Position the brake on top of drive motor (19) beingsure to mate the splines of brake (25) with thesplines of motor (19).

10. Secure disk (23) to motor (19) with three screws(27).

11. Reconnect the electrical wires to the brakeassembly.

12. Secure the cabinet door (7, Figure 12-6) closed.


R6407

1

23

456

7

9

10

11

12

13

14

15

16

817

18

12

19

20

2122

23

24

25

26

27

28

2914

30

31

323334

3536

6-2 901270

SECTION 7TRANSMISSION, DRIVE WHEEL, AND LOAD WHEEL SERVICING

7-1. DRIVE WHEEL REPLACEMENT.



3. Remove access door (1, Figure 12-6).

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

5. Remove the lug nuts and washers (1, Figure 7-1).

6. Remove the drive wheel assembly (2).

7. Position the new drive wheel on the lugs andsecure with washers and lug nuts (1).

8. Tighten the lug nuts to 58 lb ft (80 Nm).

9. Restore vehicle to operating condition.

7-2. TRANSMISSION.

7-2.1. Removal



3. Remove access door (1, Figure 12-6).

4. Remove the drain plug and drain the transmissionoil.

WARNING: Do not put fingers under the wheels orunder the frame of the vehicle.

5. With another fork lift or hydraulic jack, lift the vehi-cle until the drive wheel clears 18 inches from thefloor. Carefully slide wooden planks or steelblocks under the vehicle frame. Lower the vehicleonto the blocks but do not remove the other forklift of hydraulic jack.

6. Check to see that the vehicle is sitting securely onthe blocks and drive wheel is 18 inches off thefloor.

7. Remove the brake as described in SECTION 6.

8. Remove the drive motor as described in SEC-TION 10.

9. Remove the lug nuts and washers (1, Figure 7-1)and remove the drive wheel assembly (2).

WARNING: The transmission is very heavy. Injury tothe serviceman or damage to the trans-mission may occur if it is dropped.

10. Remove six screws (10) and remove the trans-mission (7).

11. Remove screw (3), lock washer (4), washer (5)and cam (6) from transmission (7).

7-2.2. Installation

1. Secure cam (3, Figure 7-1) to transmission (7)with screw (3), lock washer (4) and washer (5).

2. Position the transmission under the vehicle andsecure to bracket (9) with six screws (10).

3. Position drive wheel (2) on the lugs and securewith washers and lug nuts (1).

4. Tighten the lug nuts to 58 lb ft (80 Nm).

5. Install the drive motor as described in SECTION10.

6. Install the brake as described in SECTION 6.

7. Lower the vehicle to the ground.

8. Reinstall the drain plug and refill the transmissionwith oil to proper level and close the fill plug.

9. Install access door (1, Figure 12-6).

10. Check for proper operation.

901270 7-1


R6407

1

23

456

7

9

10

11

12

13

14

15

16

817

18

12

19

20

2122

23

24

25

26

27

28

2914

30

31

323334

3536

7-2 901270

7-3. LOAD WHEEL REPLACEMENT.

1. Unload the stock selector and lower the platformas far as it will go.

2. Slowly drive the vehicle straight forward on a levelfloor or surface toward a brick or concrete wall orother solid structure. Stop the vehicle with thefront an inch or two from the structure. Placeblocks behind and in front of the drive wheel sothe vehicle cannot roll.

3. Raise the platform about three feet above thefloor.

4. Turn of the key switch and disconnect the batteryplug.

5. Place 2 x 6 boards or flat steel bars on the floornext to the straddle, about six inches in front ofthe wheel to be changed.

6. Using an automotive jack or fork lift, lift the strad-dle of the vehicle about 5 or 6 inches and slide theboards under the straddle.

WARNING: Do not put fingers or toes under thestraddle or under the boards at any time.

7. Lower the vehicle so the straddle rests on theboards or bars and remove the fork lift or jack.

8. Remove the snap ring (3, Figure 7-2) from theoutside of load wheel axle (1).

9. With a large punch and a hammer, drive the axleout, being careful not to damage the axle.

NOTE: There is one washer (4) on each side of thewheel.

10. Remove the axle.

11. Lift the wheel (6) out from the top. Locate andremove the washers that were on the axle.

12. To replace a wheel, partially insert the axle andplace a washer (4) on the end inside the wheelhousing.

NOTE: There is one washer (4) on each side of thewheel.

13. Lower the new wheel into the housing and slowlywithdraw the axle until it clears the wheel, permit-ting the wheel to be lowered into position, thenpush axle through wheel, lower a washer, andengage with axle.

14. Secure the axle with snap ring (3).

15. Return vehicle to working condition.

Figure 7-2 Load Wheel

R6326

901270 7-3

7-4 901270

NOTES

SECTION 8ELEVATION SYSTEM SERVICING

8-1. GENERAL.

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

8-2. LIFT CHAIN ADJUTSTMENT

NOTE: Adjusting chain length may affect steeringcable, mechanical brake cable, and electricalcable adjustment.

1. Lower left carriage as far as it will go.


3. Remove the six screws (11, Figure 12-1) and hub(10).


5. Open lift carriage access door (16 and 18, Figure 8-1).

6. Determine which of the two chains is slack andmust be tightened.

7. Loosen the hex nut (3) on the adjusting bolt (4).

8. Turn the jam nut (1) until the chains are equallytight.

9. Tighten hex nut (3).

Figure 8-1 Lift Carriage Assembly

R6409

901270 8-1

10. Check and adjust tension of steering cable (para-graph 5-2.1.), electrical cable (paragraph 10-6.1.),and throttle valve cable (paragraph 9-6.).

11. Secure access doors.

8-3. LIFT CHAIN WEAR INSPECTION

Both lift chains should be replaced when wither chainis worn enough to increase it’s length by 3% or more.To make this determination proceed as follows.

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

For chain part # 402034: Measure the distancebetween pin centers on 20 vertical links. If the sectionmeasures 12.88” or more, the chain should bereplaced.

New chain anchor pins should be installed whenchains are replaced. Never replace a partial section ofchain and never repair a damaged chain. Refer toparagraph 8-4. when installing new chain.

8-4. LIFT CHAIN REPLACEMENT

1. Place vehicle on level surface.

2. Block wheel to prevent vehicle from rolling.

3. Raise carriage to a height of approximately threefeet.




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


8. Remove the cotter pin (29, Figure 8-2) and clevispin (31) from end of chain connected to lift cylin-der (36).

9. Remove the cotter pin and clevis pin from end ofchain connected to lift carriage (11, Figure 8-1).

10. Remove chain from sleave (19, Figure 8-2).

11. Position new chain in place on sheave.

12. Reconnect end of chain to lift cylinder (36, Figure8-2) with clevis pin (31) and cotter pin (29).

13. Connect end of chain to lift carriage adjusting bolt(32, Figure 8-1) with clevis pin and cotter pin.

14. Adjust lift chain. Refer to paragraph 8-2.

8-5. RAM HEAD REPLACEMENT.

1. Position the vehicle on a level concrete floor orsurface. Block wheels to prevent rolling.

2. Place strong steel supports under the platform tohold it three feet from the floor to permit slack inthe lift chains, and place steel blocks under thebottom edges of the inner mast to support it sol-idly.

3. Turn the key switch off and disconnect the battery.

CAUTION: All sheaves except the chain sheavescome off when the hex cap screw (10Figure 8-2) and bolt (25) are removed.

4. Remove screw (10) and bolt (25).

5. Completely disassembly as indicated in the illus-tration.

6. Reassemble by reversing the disassembly proce-dure.

8-6. LIFT CYLINDER REPLACEMENT.

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

2. Remove remaining fitting from the bottom of thelift cylinder.

3. Detach the chains from the lift cylinder by remov-ing cotter pins (29, Figure 8-2) and clevis pins(31).

4. Disconnect the overflow tube and remove anyclamps holding the overflow tube to the cylinder.

5. Remove screw (6), lockwasher (3) and washer(42) from the bottom of the lift cylinder.

WARNING: Keep fingers out of the way of the cylin-der as it descends when free.

6. Remove screw (20) and lockwasher (21) from thetop of cylinder (36).

CAUTION: The cylinder is very heavy.

7. Raise the lift cylinder (36) up and out of the mast.

8. Position the new or repaired lift cylinder in themast.

8-2 901270

Figure 8-2 Inner Mast and Ram Head

9. Secure the top of the cylinder to ram head withlockwasher (21) and screw (20).

10. Reinstall screw (6), washer (42) and lockwasher(3) to secure bottom of lift cylinder in place.

11. Reinstall fittings to the bottom of the cylinder.

12. Reinstall the flow control valve as described inparagraph 9-9.

13. Reconnect the overflow tube to the top of the cyl-inder.

14. Reconnect chains to lift cylinder with clevis pins(31) and cotter pins (29).

15. Raise the lift carriage and remove the supports.

16. Remove the blocks from the wheels.

8-7. LIFT CARIAGE REMOVAL.

1. Place vehicle on level surface.

2. Block wheel to prevent vehicle from rolling.

3. Raise carriage to a height of approximately threefeet.




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

R6408

901270 8-3


8. Remove screws (6, Figure 8-2), lock washers (3)and stops (9) from the top of the mast.

9. Remove the cotter pins and clevis pins from endof chain connected to lift carriage (11, Figure 8-1).

10. Remove lift carriage from mast using a chainhoist.

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

12. Adjust lift chain. Refer to paragraph 8-2.

8-8. LIFT CARIAGE DISASEMBLY.

Refer to Figure 8-1 as a guide in disassembly and toidentify replacement parts.

8-4 901270

SECTION 9HYDRAULIC SYSTEM SERVICING

9-1. GERNERAL.

Primary components of the hydraulic system are thereservoir, filter, pump, check and relief valves, throttlevalve, hangup valve, hydraulic lift cylinder, flow controlvalve, and accumulator. Activating the LIFT switchapplies battery voltage to the pump motor relay, ener-gizing it to start the pump motor. The pump then drawshydraulic oil from the reservoir through the flow controlvalve to the hydraulic lift cylinder. The accumulatorsmooths out momentary fluid pressure surges bymeans of an internal bladder that allows it to absorb asmall quantity of hydraulic oil, which is released whenthe pressure falls. The pump continues to function,and the cylinder lifts the platform until the LIFT switchis released or the platform reaches its maximumheight. When pump pressure stops, a check valvecloses due to the back pressure of the cylinder, thehydraulic oil cannot flow back out of the cylinder andthe platform remains at the raised position. At this time

the relief valve and throttle valve are both closed, pre-venting the oil from flowing out of the lift cylinder.

Pushing the lowering valve lever toward DOWN opensthe throttle valve. This permits the hydraulic oil flowback from the lift cylinder, through the flow controlvalve, hangup valve, and throttle valve back into thereservoir, letting the platform descent. The flow controlvalve is preset to the maximum desirable loweringspeed. The hangup valve is a safety device. This valveis operated by the hydraulic pressure applied to it bythe weight of the descending platform. If the platformstrikes an obstruction while descending and hangs upon the obstruction, the decrease in hydraulic pressurecauses the valve to close. This stops the downwardmotion of the cylinder and mast, preventing the chainsand cables from coming loose. The relief valve is setto provide sufficient hydraulic pressure to lift the ratedload, but excessive pressure causes the relief valve toopen, and allows the oil to flow back into the reservoir.

Figure 9-1 Hydraulic Schematic Diagram

R6377

901270 9-1

9-2. SUMP FILTER REPLACEMENT.

1. Lower the lift carriage to the lowest position.

2. Turn off key switch and disconnect battery.

3. Open the door to the electrical compartment.

NOTE: A small funnel with a few feet of 1/2-inch hosewill facilitate draining oil from the reservoir.

4. Drain the hydraulic oil from the reservoir into aclean bucket or suitable container.

5. Disconnect the suction tube (31, Figure 9-2) fromnipple (32).

6. Unscrew filter (33) from the reservoir.

7. Clean filter (33) and thread back into the reser-voir.

8. Reconnect the lines and return the vehicle to nor-mal working conditions.

9-3. HANDUP VALVE REPLACEMENT.




4. Disconnect hose (1, Figure 9-2) and elbow (2)from hangup valve (3).

5. Disconnect hangup valve from nipple (4) andinstall new valve.

6. Reconnect elbow (2) and hose (1) and returnvehicle to normal working condition.

9-4. ACCUMULATOR SERVICING AND RECHARG-ING

9-4.1. General

The accumulator has been factory precharged to apressure of 400 psi for the most efficient operationunder average operation of the Stock Selector LiftTruck.

NOTE: If accumulator need recharging, see yourlocal Big Joe dealer or recharge with nitrogengas to approximately 400 psi then adjust foroptimum precharge pressure as explained inthis paragraph.

The following procedure can be used to check the pre-charge or to increase the shock absorption capabili-ties.

CAUTION: Too much bleeding will result in exces-sive lifting lag and load float. Anunloaded accumulator precharge pres-sure of less than 400 psi will shorten thelife of the accumulator bladder andcause premature failure.

9-4.2. Precharge Adjustment

Checking or adjusting precharge pressure requires aCharging and Gauging Assembly. Consult your localBig Joe dealer.

An average load for the Stock Selector should be usedwhen adjusting precharge. For efficient shock absorp-tion, precharge pressure should be approximately two-thirds the lifting pressure of average load.

1. Remove gas valve cover and cap from accumula-tor.

NOTE: Make sure carriage is at lowest position andhydraulic line pressure is at zero.

2. Mount gauging head and check precharge pres-sure of the accumulator.

3. Lift load and observe maximum pressure ongauge while lifting. The precharge should beapproximately two-thirds of this valve for the firstsetting.

4. Raise load approximately six feet.

5. Drop load (free fall, do not throttle).

6. Stop load approximately three feet from ground(floor). No sudden stoppage should be observedand a downward “float” of approximately one andone-half inches to three inches should be evident.

NOTE: Additional bleeding may be necessary toattain desired cushioning. This should beaccomplished through “trail and error”method using 25 psi reductions of prechargepressure each time until the best operatingpressure is attained.

9-2 901270

Figure 9-2 Hydraulic System

9-5. HYDRAULIC PRESSURE ADJUSTMENT

WARNING: Improper setting of the hydraulic pres-sure by an unauthorized person can voidyour Big Joe guarantee.

The relief valve is factory set to open beyond the ratedpressure setting for the pump (not to exceed 2150 psi)and rarely needs adjusting. If you suspect that therelief valve in the pump is malfunctioning, perform thefollowing procedures.

CAUTION: A pressure gauge and suitable tee mustbe used.

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

2. Disconnect hose (6, Figure 9-2) from coupling (7)and connect a suitable tee with pressure gauge ofadequate range (0-3000 psi) between hose (6)and coupling (7).

3. Active pump motor and observe reading on pres-sure gauge. If pressure reading is between 2050and 2150 psi, the relief valve is functioning prop-

erly and does not need adjustment; deactivatepump motor, disconnect gauge and tee, andreconnect hose. If pressure reading is below 2050psi or above 2150 psi, proceed as follows toadjust relief valve.

CAUTION: Do not set pressure too high or liftassembly and hydraulic system may bedamaged. Factory recommended limitsof 2050 to 2150 psi should be observed.Under no circumstances should pres-sure be set above 2150 psi.

4. Loosen locknut at top of adjustable relief valve(13). With pump motor running, observe pressuregauge and set pressure between 2050 and 2150psi by turning adjusting screw in or out, asrequired. Tighten locknut when desired pressureis obtained.

5. Deactivate pump motor, disconnect gauge andtee and reconnect hose.

R6410

901270 9-3

9-6. THROTTLE VALVE ADJUSTMENT

The throttle valve is properly adjusted, inspected andchecked thoroughly before leaving factory. If adjust-ment is necessary, proceed as follows:

1. Raise lift carriage part way with a moderate loadon the forks to build up pressure in hydraulic sys-tem.

2. Leave lowering valve in its neutral position.

3. Check the throttle control cable (31, Figure 9-3)for excess play. Take up any play by adjustingturnbuckle (28).

NOTE: Clevis pin (12) maintains spring (15) undercompression.

4. Remove cotter pin (10) and first washer (9).

5. Withdraw clevis pin (12) and second washer (9).

6. Grasping actuating arm of throttle valve (8), rotaterelease cam (9, Figure 9-5) 1/8 turn counterclock-wise to make sure that check ball is seated.

NOTE: Turning the release cam counterclockwisemoves pin down against check ball. When pinrests on the check ball, hydraulic pressure inthe system provides the resistance felt in step7. Turning the release cam beyond this pointpushes the check ball from the valve seat.

7. Rotate release cam counterclockwise until a defi-nite resistance is felt.

8. Mark the position of the actuating arm (6) relativeto the valve body with a pencil mark.

9. Reconnect the cable to the actuating arm byreplacing clevis pin, washers, and cotter pin.

10. Set actuating arm to the orientation indicated bythe pencil mark by adjusting the two nuts (13, Fig-ure 9-3) on side of spring (15) near throttle valve(8). Tighten the two nuts (27 and 29) on eitherside of turnbuckle when finished.

11. Test adjustment by pushing lowering valve for-ward approximately one inch. Lift carriage shoulddescend slowly.


R6411

9-4 901270

9-7. THROTTLE VALVE REPLACEMENT

1. Lower lift carriage fully.

2. Turn off the key switch and disconnect the battery.


3. Disconnect nipple (10, Figure 9-2) and elbow (8)from throttle valve (22).

NOTE: Clevis pin (12, Figure 9-3) holds spring (15)under compression.

4. Remove cotter pin (10) and one washer (9).

5. Free throttle valve (8) by removing four hex headcap screws (3) and lock washers (4).

6. Remove compression spring (1, Figure 9-5),check ball (2) and valve pin (3).

7. Remove screw (8); then the actuating arm (6),plate (7), release cam (9), and O-ring (10) can bepulled from valve body (11).

8. If necessary, remove roll pin (5) and plug (4) tocomplete disassembly.

9. Inspect for and replace worn parts.

10. Reassemble by reversing disassembly procedure.

11. Check adjustment of throttle valve (paragraph 9-6.)

9-8. THROTTLE VALVE ACTUATOR REPAIR



3. Remove four screws (3) securing the dash coverplate (4).

4. Move the dash cover plate (4)out and disconnectharness (2) from steering wheel and columnassembly (1).

5. Remove dash cover plate (4) with steering wheeland column assembly (1).

Figure 9-4 Dash Removal

6. To disassemble the throttle valve actuator,release tension from throttle control cable (17,Figure 9-3) by removing two nuts (13) and springwasher (14) on valve (8) side of bracket. Removeknob (23) and two screws (20).

7. Completely disassemble as indicated in Figure 9-5).

8. Replace defective parts and reassemble inreverse order of disassembly.

12

3

4

R6428

901270 9-5

Figure 9-5 Throttle Valve Assembly

9-9. FLOW REGULATOR VALVE REPLACEMENT

1. Position the vehicle on a level floor or surface.Block wheels to prevent rolling.

2. Raise platform and place strong steel supportsunder the platform to support it three feet from thefloor, lower the platform onto the supports. Checkthat the supports are secure and that platform islowered as far as it will go using the lift control.Pace steel blocks under the bottom edges of theinner mast to support it solidly.

3. Turn key switch off and disconnect the battery.

4. Place any container suitable for catching a fewpints of oil under flow control valve (45, Figure 9-2).

5. Disconnect pressure hose (44) and allow fluid todrain into container.

6. Remove reducer (44) from flow control valve (45).

7. Disconnect flow control valve (45) from reducer(44).

8. Install new flow control valve and reducer (44).

9. Reconnect pressure hose.

10. Refill oil reservoir.

11. Reconnect battery, turn key switch on and acti-vate LIFT control to raise platform.

12. Unblock wheels and free vehicle from steel blocksand supports.

9-10.HYDRAULIC PUMP AND MOTOR ASSEMBLY

Portions of the hydraulic pump and motor assemblymay be repaired. A new set of brushes may beinstalled in the motor without disassembling the motorand pump assembly. The motor can be rebuilt, but adefective pump has to be replaced as a complete unit.If the hydraulic pump and motor assembly is disas-sembled, the gasket (3, Figure 9-6) must be replaced.

Proceed as follows to remove and replace the pumpand motor assembly.





4. Remove drain plug and drain hydraulic oil fromthe reservoir into a clean bucket or suitable con-tainer.

5. Identify each pump motor electrical lead with amarker.

R6334

9-6 901270

6. Disconnect the electrical leads from the pumpmotor.

WARNING: Before disconnecting any hydraulic lines,make certain the system is not underpressure.

7. Refer to Figure 9-2 and disconnect all lines andfittings from the pump and motor assembly.

8. Remove the four nuts (26), lock washers (27),washers (37) and screws (42) and lift the pumpand motor assembly out of the vehicle.

9. Separate the pump from the motor by removingthe four hex head cap screws (6, Figure 9-6) andlock washers (5). Discard gasket (3), but set asidedrive connector (2).

10. If the pump is defective, install a new pump. Ifmotor is defective, a new motor may be installed,or motor may be rebuilt (see paragraph 10-7.).

11. Reassemble in truck and complete reassembly byreversing the sequence of the disassembly proce-dure.

Figure 9-6 Pump and Motor Assembly

R6413

901270 9-7

9-11.LIFT CYLINDER REPAIR

NOTE: Removal and installation of the lift cylinder isdescribed in SECTION 8.

12. Unthread support ring (3) with wiper ring (2).These parts may then separated.

13. Remove O-ring (4).

14. Pull out cylinder ram (6).

15. Remove stop (5) from ram (6).

16. Remove nut (11), piston (9), and O-ring (7).

17. Remove wear ring (10) and seal (8) from piston(9).

NOTE: It is recommended that wiper ring (2), O-ring(4), O-ring (7), seal (8) and wear ring (10) bereplaced before the hydraulic lift cylinder isreassembled.

18. Clean all parts with solvent and dry with com-pressed air.

19. Inspect for scored, cracked, or deeply scratchedpiston, ram, and support ring for cracks.

20. To reassemble, reverse the sequence of disas-sembly.

Figure 9-7 Lift Cylinder

R6412

1

6

7

11

2

3

4

510

8

9

PACKING KIT PART NUMBER

907181 CONTAINS:

ITEM QTY2 14 17 18 1

10 111 1

9-8 901270

SECTION 10ELECTRICAL COMPONENTS

10-1.HIGH SPEED LIMIT SWITCH.

10-1.1.Operational Check

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

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

2. Drive at a moderate speed, then push SPEEDcontrol lever to highest speed position. The rate oftravel should not increase to top speed.

3. Stop and then lower the lift carriage to approxi-mately 24 inches above the floor.

4. Drive at moderate speed, then push SPEED con-trol to highest speed position. The rate of travelshould increase to top speed.

10-1.2.High Speed Limit Switch Adjustment

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

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

2. Check that switch roller is contacting the barwelded on the inner mast face and has closed theswitch contacts (switch should not click whenroller arm is manually moved farther towardswitch body). When roller arm is manually movedtoward switch body, there should be at least 1/16inch clearance between roller and bar on innermast face.

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

3. If roller does not contact bar on inner mast face orif switch clicks when roller is manually movedtoward the switch body, loosen locknut on theroller arm, adjust roller arm away from switchbody, and tighten locknut.

4. If switch roller cannot be manually moved to clearthe bar on the inner mast face, loosen locknut onthe roller arm, adjust roller arm toward switchbody, and tighten locknut.

5. Repeat step 2. to check adjustment.

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

7. Check that switch roller is not touching the innermast face and has opened switch contacts (listenfor audible click when roller arm is manuallymoved toward switch body and another clickwhen released).

8. If roller arm touches inner mast face, loosen lock-nut on the roller arm, adjust roller arm towardswitch body, and tighten locknut.

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

10. Repeat step 2. to check adjustment.

10-2.EMERGENCY POWER DISCONNECT

10-2.1.Disconnect Switch



3. Remove four screws (25, Figure 10-1) and movecover (19) out.

4. Tag and disconnect the leads from EPD switch(20).

5. Disconnect harness (5) from harness (34).

6. Remove the two screws (24) and lock washers(23) securing EPD switch (20) to cover (19).

7. Install in reverse order of removal.

10-2.2.Reset Switch



3. Open the electrical compartment cabinet door.

4. Tag and disconnect the leads from emergencypower disconnect reset switch (12, Figure 10-2).

5. Remove the two screws (10) and spacers (11)securing switch (12).


10-2.3.EPD Panel Assembly




4. Tag and disconnect the leads from EPD panel(23, Figure 10-2).

901270 10-1

5. Remove three nuts (25) and lock washers (24)securing panel (23).

6. Refer to Figure 10-3 for disassembly of the panel.


Figure 10-1 Controls

R6416

1

1

234

56

78

9 10

11,1213

14

15

16

17

18

19

20

21

22

2324

25

526272

475

28

29

3018

31

32

5

3334

3536

5

10-2 901270


Figure 10-3 EPD Panel

R6419

A

P

B+

B-

CB

A

R

S

FWD

CNTCR

REV CNTCR

A

APUMP CNTCTR

CNTCTR

BYPASS

VIEW A-A

123

4

121

3736

19

13

5

6

78

910

1112

3334

35

1

13

214

1516

17

18

19

2021

14

22

2928

27

26

30

27

31

32

3534



2324

25

R6421

MAX. 300 A

DELAY TYP

1

2

3

24

23

22

21 2019,20

15,16,17

11

12

25

9,10

87264,5,6

901270 10-3

10-3.ELECTRICAL CONTROL PANEL

10-3.1.Electrical Panel Assembly




4. Tag and disconnect the leads from electricalpanel (22, Figure 10-2).

5. Remove four screws (20) and lock washers (21)securing panel (22).

6. Refer to Figure 10-4 for disassembly of the panel.


Refer to SECTION 4 for troubleshooting and adjust-ment of the Sevcon PowerpaK controller.

Figure 10-4 Electrical Control Panel

R6420

10-4 901270

10-4.JOYSTICK CONTROLLER

10-4.1.Replacement




4. Tag and disconnect the leads from EPD switch(20).

5. Disconnect harness (5) from harness (34).

6. Remove the two screws and washers securingcontroller (35) to cover (19).


10-5.FULL FEATURE DISPLAY




4. Disconnect harness (1) from steering column (7)and move cover (18) out of the way.

5. Disconnect harness (1) from full feature display(3).

6. Remove two nuts, two lock washers and mount-ing bracket from display (3) and remove the dis-play.


10-6.ELECTRICAL CABLE MAINTENANCE

10-6.1.Electrical Cable Tension Adjustment

1. Raise lift carriage to gain access to electricalcable tension bracket mounted on the base of thestock selector.

2. Block lift carriage in raised position to preventaccidental lowering.

3. Loosen screws on clamp (4, Figure 10-1), allow-ing spring (3) to extend to its relaxed position.

4. Pull downward on electrical cable (2) from belowto eliminate slack, but do not pull taut.


R6404

1

23

4

56

71

1314

18

11920

21

22

2324

25

2627

28

28

2922

30

21

817

16

9

10

11 12

15

901270 10-5

5. Move clamp (4) and spring (3) up to top of bracketand, while compressing spring, tighten screws onclamp (4). When released, spring (3) should pullcable taut.

6. If spring and clamp do not move, cable was pulledtoo taut; if spring expands fully, slack was notremoved. Repeat steps 3. through 5.

7. Remove blocks and lower lift carriage.

10-6.2.Replacement of Electrical Cable

Replace the cable according to the following proce-dure.



3. Raise the carriage to a height of three to six feetto be able to work under it.






9. Disconnect harness (1) from steering column (7)and move cover (18) out of the way.


11. Disconnect cable (5, Figure 10-1) from receptacle(26).

12. Cut wires of cable (2) at receptacle (26) leavingsufficient wire to identify wire to identify wire colorcode.

13. Loosen screws on strain relief (4) located on thecarriage and pull cable (2) out the bottom of thestrain relief and free of the J tube.


15. Disconnect cable (19, Figure 10-2) from harness(16).


17. Loosen screws on strain relief (4, Figure 10-1)located on the carriage and pull cable (2) up and

out of bracket. Spring (3) and strain relief (4) willfall free.

18. Lift the cable free of its sheave on the ram head.

19. Lay old cable along the ground, measure it andcut new cable to this length, allowing severalextra inches to facilitate fitting and to account forlengths of wire cut off at connectors.

20. Route the length of the cable over its sheave onthe ram head and down through the bracket,spring (3) and strain relief (4). Do not securestrain relief at this time.

21. Route the cable into the frame.


23. Strip the end of the each wire and crimp new con-tact (18, Figure 10-2)



25. Connect receptacle (17) to harness (16).

26. Route the cable through the J tube and upthrough relief (4, Figure 10-1).


28. Strip the end of the each wire and crimp new con-tact (27)



30. Connect receptacle (26) to harness (5).

31. Secure the cable with strain relief (4).

32. Adjust the cable tension a described in paragraph10-6.1..

33. Secure cabinet door (7, Figure 12-6) closed.

34. Close and secure the cabinet doors located belowthe steering wheel.

10-6 901270

35. Move cover (18, Figure 10-5) into position andreconnect harness (1) from steering column (7).

36. Secure cover (18) with four screws (14).

10-7.PUMP MOTOR

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

The pump motors do not require lubrication. If themotor is defective, remove cover band and inspectbrushes and commutator. Replace set of brushes ifthey are worn down to 1/4 inch. Clean commutator ofrough spots with a fine emery cloth. Refer to Figure12-18 for motor disassembly.

10-8.DRIVE MOTOR

The drive motor requires little periodic maintenance. Ifthe stock selector does not run and the drive motor isat fault, remove cover band and inspect brushes andcommutator Brushes should be replaced if they areworn down to 0.57 inches. Remove motor from truckby following the procedure in paragraph 10-8.1. below.Refer to paragraph 10-8.2. for motor repair.

10-8.1.Motor Removal

Remove motor from transmission as follows:

1. Remove the brake as described in SECTION 6.

2. Tag and disconnect the leads from drive motor(19, Figure 12-5).

3. Remove six screws (26) and washers (14).

4. Remove motor (19) and plate (18).

5. Restore stock selector to working condition byreversing the sequence of step in this procedure

10-8.2.Motor Repair

If the truck does not run and the drive motor is at fault,disconnect the battery, remove drive motor cover bandand inspect brushes, brush spring, and commutator.

10-8.2.1. Brushes

Brushes should measure between 0.57 and 1.38inches. Replace brushes if length approaches the min-imum value.

10-8.2.2. Brush Springs

Correct brush spring tension is between 16 and 36ounces. The maximum value is for new brushes orbrushes near maximum acceptable length. The mini-mum specified tension is for brushes near the mini-mum acceptable length.

Measure spring tension with a spring scale hookedunder the brush spring at the brush. Pull the scale on aline opposite the line of force exerted by the brushspring and take the reading just as the spring leavesthe brush.

10-8.2.3. Commutator

Clean the commutator of rough spots with a fine sand-paper and remove accumulation of loose particles.The diameter of the commutator should be checkedafter cleaning. If the diameter is 2.810 inches or largerfor motor part number 016035 or (2.935 inches largerfor motor part number 016031), reslotting and refinish-ing is recommended. If diameter is less than 2.750inches for motor part number 016035 or 2.874 inchesor less for motor part number 016031, replacement isrequired.

10-8.2.4. Electrical Measurements

FIELD COIL TEST - Measure resistance between ter-minals S1 and S2 with a bridge. Resistance should bebetween 0.0076 ohms and 0.0086 ohms for motor partnumber 016035 and between 0.0062 and 0.0070ohms for motor part number 016031.

ARMATURE TEST - The new drive motor armaturecan be tested for shorts using a standard growler andmetal strip or hacksaw blade.

901270 10-7

NOTES

10-8 901270

SECTION 11OPPTIONAL EQUIPMENT

11-1.FLASHING RED LIGHT.

The flashing red light or optional red strobe light ismounted on top of the electrical compartment.

The flasher is part of the light. Refer to the Figure 12-22 as a guide in disassembly and to identify replace-ment parts.

11-2.SIDE GUIDE ROLLERS.

The side guide rollers are an optional accessory. Bothsteel and polyurethane rollers are used. The steel typeare mounted under the stock selector as shown inFigure 11-1 and the polyurethane type are mounted onthe side as shown in Figure 11-2.

11-2.1. Steel Roller Replacement

Remove the steel guide rollers by removing the threescrews (3, Figure 11-1) and center mount (2), releas-ing the side guide roller (1).

11-2.2. Polyurethane Roller Replacement

The polyurethane side guide rollers are replaced asfollows:

1. Remove the retaining ring (1, Figure 11-2).

2. Lift out axle (2) with pin (6). This will free spacers(3), wheel (5), and bearing (4).

3. Slide axle (2) through the hole in housing (7), andplace spacers (3), wheel (5), and bearings (4) onaxle.

4. Place the retaining ring (1) on axle.

Figure 11-1 Side Guide Roller (Steel)

Figure 11-2 Side Guide Roller (Polyurethane)

R6358

R6363

901270 11-1

11-3.SAFETY HARNESS

The safety harness has shoulder straps that areadjustable to fit the individual operator. In use thesafety lanyard is attached to the special 1/2-inch-diam-eter rod of the overhead guard as shown in Figure 11-4, and the other end of the lanyard is attached to thering in the safety harness.

Figure 11-3 Operator Safety Harness

11-4.SAFETY BELT

The safety harness has shoulder straps that areadjustable to fit the individual operator. In use thesafety lanyard is attached to the special 1/2-inch-diam-eter rod of the overhead guard as shown in Figure 11-4, and the other end of the lanyard is attached to thering in the safety harness.

Figure 11-4 Operator Safety Belt

R6418 R6438

11-2 901270

11-5.PALLET CLAMP

The pallet clamp is an optional accessory. No particu-lar disassembly procedure is recommended. Refer to

Figure 11-5 as a guide in disassembly and to identifyreplacement parts.

Figure 11-5 Pallet Clamp

R6361

901270 11-3

11-6.SLIP ON PLATFORM

The slip on platform is attached to the lift carriage. Thearrangement of safety chains must be as shown inFigure 11-6.

Figure 11-6 Slip On Platform

R6262

11-4 901270

SECTION 12ILLUSTRATED PARTS BREAKDOWN

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

901270 12-1


R6404

1

23

4

56

71

1314

18

11920

21

22

2324

25

2627

28

28

2922

30

21

817

16

9

10

11 12

15

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 023291 HARNESS ASSY-STEERING/DISPLAY

1

2 023295 HARNESS ASSY-DISPLAY 1

3 015616 DISPLAY-FULL FEATURE 1

4 059936 NUT-“U” SPEED 4

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

6 077209 WASHER-LOCK, SPLIT, 1/4 4

— 800322 STEERING WHEEL & COLUMN ASSEMBLY

1

7 — . STEERING COLUMN (FIGURE 12-2)

REF

8 — . HUB 1

9 — . STEERING WHEEL 1

10 — . SCREW 3

11 — . COVER 1

12 — . SCREW 6

13 404905-01 TUBING 4

14 072407 SCREW-SHT MET, #10 B X 3/4 4

15 063485 SCREW-HEX CAP, 1/4-20 X 2 4

16 057709 HANDLE, FOLDING 1

17 059537 NUT-HEX, JAM 1/2-13 1

18 404715 PLATE-COVER, DASH 1

19 005641 RECEPTACLE-FLANGED, 16 PIN 2

20 005643 CONTACT-PIN (NOT SHOWN) 8

21 004705 CABLE-12 CNDCT, 18 GA, 0.472 O.D.

A/R

22 005414 STRAIN RELIEF 2

23 070475 SCREW-PH RD HD, 1/4-20 X 3/8 1


25 056144 CLAMP-CABLE, 1/2 1

26 504979 SHEAVE ASSY-CABLE 1

27 402769 BOLT-SHOULDER 1

28 057512 GROMMET-RUBBER, 1-1/4” ID 2

29 075035 SPRING-ADJUSTING, CABLE TENSION

2

30 — LIFT CARRIAGE (FIGURE 12-11) REF

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-2 901270

Figure 12-2 Steering Column Rework

R6405

WIRE #2AWIRE #2A

TO PIN #2TO PIN #2

WIRE #4AWIRE #4A

TO PIN #4TO PIN #4

WIRE #1AWIRE #1A

TO PIN #1TO PIN #1

WIRE #3AWIRE #3A

TO PIN #3TO PIN #3

12.00+.50-.00

SEE NOTESEE NOTE

JUMPER (TO 3A)JUMPER (TO 3A)JUMPER (TO 2A)JUMPER (TO 2A)

VIEW OF POTENTIONETER TERMINALSVIEW OF POTENTIONETER TERMINALS

WIRES TO BE SOLDERED TO THE (6)WIRES TO BE SOLDERED TO THE (6)POTENTIOMETER TERMINALS.

NOTE:

STEERING WHEEL REMOVED,STEERING WHEEL REMOVED,SHOWN UPSIDEDOWN

12

34

1

A2

A3

A4

A

1A

3A4A2A

(WIRING DETAIL)(WIRING DETAIL)

2

3

4

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 — STEERING COLUMN (FIGURE 12-1)

REF

2 005676 HOUSING-PIN 1

3 005262 CONTACT-PIN 4

4 023018 WIRE-16 AWG STRANDED, BLACK

A/R

A/R - AS REQUIRED

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-3

Figure 12-3 Controls

R6416

1

1

234

56

78

9 10

11,1213

14

15

16

17

18

19

20

21

22

2324

25

526272

475

28

29

3018

31

32

5

3334

3536

5

12-4 901270

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 057512 GROMMET-RUBBER, 1-1/4 ID 2

2 004730 ELECTRICAL CONTROL CABLE A/R

3 075035 SPRING-ADJUSTING, CABLE TENSION

1

4 005414 RELIEF-STRAIN, 3/4 2

5 023290 HARNESS ASSY-CONTROL, PLATFORM

1

6 — DISPLAY (FIGURE 12-1) REF

7 021252 TERMINAL-SLIP ON, 1/4” FULL INS

3

8 013607 LIGHT-INDICATOR, 24V 1

9 021203 TERMINAL-RING, 3/16, 16 GA 1


11 021263 TERMINAL STRIP-5 SCREWS 1

12 021264 JUMPER-RJ TYPE, 5 SCREWS 1

13 077205 WASHER-LOCK, SPLIT, #8 2

14 070491 SCREW-PH RD HD, 8-32 X 7/8 2

15 056690 DECAL-DIRECTIONAL 1

16 506464 BRACKET WELDMT-HANDLE 1

17 063478 SCREW-HEX HD, 1/4-20 X 3/4 1


19 404716 COVER-CONTROL ENCLOSURE 1

20 020698 SWITCH-PUSHBUTTON, RED 1

21 074712 SPACER-NYLON, #6 X 0.25 LG 2

22 056627 DECAL-EPD 1


24 068231 SCREW-SL RD HD, 6-32 X 1/2 2

25 072407 SCREW-SHT MET, #10 B X 3/4 4



28 005405 RELIEF-STRAIN, 3/8” 1

29 020703 SWITCH-LIMIT 1

30 070475 SCREW-PH RD HD, 1/4-20 X 3/8 2

31 056116 CLAMP-CABLE 1

32 023293 HARNESS ASSY-KEY & LIGHT 1

33 020725 SWITCH-KEY 1

34 023292 HARNESS ASSY-DIRECTIONAL CONTROL

1

35 020804 CONTROLLER-JOYSTICK 1

36 059936 NUT-”U” SPEED 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-5


12

34

5

6

67

8

9

10

11

12

R6417

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 005405 RELIEF-STRAIN, 3/8” 1

2 506465 CABLE ASSY-BRAKE 1

3 071379 SCREW-PH TR HD, 10-32 X 1/4 2

4 255806 MAT-PEDAL, BRAKE 1

5 506439 BRAKE PEDAL WELDMT 1

6 020729 SWITCH-DEADMAN 1

7 075059 SPRING-EXTENSION, BRAKE 1

8 400048 STUD-THREADED 1

9 059629 LOCK NUT, 3/8-16 2


11 065477 HEX SOCKET CAP SCREW 2


INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-6 901270

NOTES

901270 12-7


R6407

1

23

456

7

9

10

11

12

13

14

15

16

817

18

12

19

20

2122

23

24

25

26

27

28

2914

30

31

323334

3536

12-8 901270

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 059901 KIT-WHEEL MOUNTING HARD-WARE

1

2 079169-02 WHEEL-DRIVE, POLY, SMOOTH CROWN (STANDARD)

1

2 079169-01 WHEEL-DRIVE, POLY, SMOOTH FLAT (STANDARD)

1

3 063482 SCREW-HEX HEAD CAP 1


5 077031 WASHER 1

6 404902 CAM-SWITCH, STEERING 1

7 506395 TRANSMISSION ASSY-GK20 1

8 — . STEERING GEAR 1

9 506434 WELDMENT-TRANSMISSION MTG BRACKET

1

10 067446-01 SCREW-HEX SOC HD, M12, 30LG 6

11 069950 SCREW-SOC HEAD, 3/4-16, 4”LG 4

12 061051 ROLL PIN, 3/8DIA X 1”LG 10

13 404901 PLATE-ADAPTER, SPACER 1


15 064611 SCREW-HEX CAP, 3/8-16 X 1-1/2, HEAT TREATED

4

— 005675 POWER STEERING REGULATOR 1

16 — . REGULATOR 1

17 059480-01 . NUT 1

18 404900 PLATE-ADAPTER, SPACER, MOTOR

1

19 — MOTOR-DRIVE, 24V (FIGURE 12-19)

REF

20 057900-03 KEY 1

21 404919 SPACER 1

22 061719 RING-SNAP, EXT., 3/4” DIA 1

23 404903 DISK-ADAPTER, MOTOR & BRAKE

1

24 021257 TERMINAL, TAB MALE, 1/4 INSULATED

2

25 052826 BRAKE-ELECTRIC 1

26 059421 NUT-HEX, 1/4-20 4

27 067435-03 SCREW-CAP, HX SOC FL HD, M8, 25L

3

28 069481 SCREW-PH FL HD, 1/4-20 X 1-1/4 4

29 064615 SCREW-HEX CAP, 3/8-16 X 2-1/4 6

30 068234 SCREW-MACH, SLOTTED, RD HD 2

31 020673 SWITCH-DEADMAN 1

32 077007 WASHER 2


34 059412 NUT-HEX, 6-32 2


36 059447 NUT-HEX, 3/4-16 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-9

Figure 12-6 Base, Frame and Plates

R6414

12-10 901270

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 111773 DOOR-ACCESS 1

2 069602 MACH. SCREW-PH, FLAT HD 4

3 059416 NUT-HEX, 10-32 4


5 071376 SCREW-PH TR HD, 10-32 X 1/2 4

6 055500 CATCH-FASTENER, DOOR 1

7 501271 DOOR WELDMENT-CABINET 1

8 077056 WASHER-7/16 X 1 X 14 GA 3

9 077011 WASHER-3/8 X 7/8 X 14 GA 3


11 059426 NUT-HEX, 5/16-18 3

12 503334 ELECTRICAL COMPARTMENT ACCESS COVER

1

13 069480 SCREW-PH FL HD, 1/4-20 X 1 6

14 003140 BATTERY, 24V, 340AH, WET(10.81” X 25.19” X 23.25”)

1


1

14 003136 BATTERY, 24V, 425AH, DRY(10.81” X 31.87” X 23.25”)

1


1

15 055630 CHAIN (1.125 IN.) 2

16 400802 PIN-LOCK, RETAINER, BATTERY 2

17 400801 HINGE PIN 2

18 060407 COTTER PIN 6

19 504981 RETAINER WLDMT-BATTERY (25.19” LONG BATTERY - 2000#)

2

19 505239 RETAINER WLDMT-BATTERY (25.19” LONG BATTERY - 3000#)

2

19 503577 RETAINER WLDMT-BATTERY (31.87” LONG BATTERY)

2

19 503577 RETAINER WLDMT-BATTERY (30.56” LONG BATTERY)

2

20 058100 LATCH-DOOR 1

21 VAR FRAME WELDMT 1

— 505175-01 BATTERY SPACER (340AH BATTERY - 2000#)

1

— 505175-02 BATTERY SPACER (425AH BATTERY - 2000#)

1

— 505175-03 BATTERY SPACER (340/425AH BATTERY - 3000#)

1

— 505175-04 BATTERY SPACER (510AH BATTERY - ALL CAP.)

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-11

Figure 12-7 Battery Rollout

R6437

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 — CHAIN (1.125 IN.) (FIGURE 12-6) REF

2 — PIN,-LOCK, RETAINER, BAT-TERY (FIGURE 12-6)

REF

3 — HINGE PIN (FIGURE 12-6) REF

4 — COTTER PIN (FIGURE 12-6) REF

5 — RETAINER WLDMT-BATTERY (FIGURE 12-6)

REF

6 063478 SCREW-HEX HD, 1/4-20 X 3/4 4

7 077209 WASHER-LOCK, SPLIT 4

8 077031 WASHER-5/16 X 3/4 X 16 GA 4

9 302507 PIPE-2 7

10 051185 BEARING-PLASTIC, TUBING 14

11 270119 SHAFT-ROLLER 7

12 073461 SCREW-SET, #10-24 X 3/8 LG 7

13 501913 ROLLER TRAY 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-12 901270

Figure 12-8 Decals

R6415

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 056626 DECAL-OIL LEVEL 1

2 056564 DECAL-CAUTION, ACCESS PANEL

2

3 056631 DECAL-DOOR 1

4 056629 DECAL-LOWERING, EMERGENCY, SSC

1

5 056654 DECAL-NOTICE, E.P.D. 1

6 056646 DECAL-CAUTION, BATTERY 1

7 — SAFETY HARNESS & LANYARD INSTL (FIGURE 12-31)

REF

8 056633 DECAL-MAST, BIG JOE, LRG 2

9 056677 DECAL-WARNING, PINCH, VERTICAL

3

10 056588 DECAL-SSC/SSCM SAFETY MYLAR

1

11 061337 NAMEPLATE-SSC 1

12 066050 SCREW-DRIVE, RH HD, #2 U X 1/4

4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-13

Figure 12-9 Load Wheel

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 401095 AXLE 2

2 060970 ROLL PIN 2

3 061730 SNAP RING 2

4 077074 FLAT WASHER 4

— 078635 LOAD WHEEL 2

5 051220 . BALL BEARING 2

6 078634 . LOAD WHEEL 1

R6326

12-14 901270

NOTES

901270 12-15

Figure 12-10 Inner Mast and Ram Head

R6408

12-16 901270

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 VAR FRAME WELDMENT REF

2 313001 ANGLE SUPPORT 1

3 077410 WASHER-LOCK, 3/8 EXT TOOTH 10

4 063603 SCREW-HEX HD, 3/8-16 X 3/4 2

5 VAR INNER MAST 1

6 064605 SCREW-HEX HD, 3/8-16 X 1 1

7 062320 BEARING, MAST ROLLER 4

8 077077 WASHER, 7 GA A/R

8 077078 WASHER, 9 GA A/R

8 077079 WASHER, 11 GA A/R

8 077080 WASHER, 14 GA A/R

9 314403 LIFT CARRAGE STOP 2

10 402991 SCREW-HEX HEAD CAP, 5/8-11 X 3-1/2

3

11 074270 PULLEY-THROTTLE CONTROL 1

12 051233 WASHER-THRUST BEARING 2

13 800134 ELECTRICAL CABLE SHEAVE 2

14 059237 BUSHING 1

15 402610-03 TUBE-SPACER 1

16 061729 RING-RETAINER 2

17 051210 BEARING-SHEAVE 2

18 053013 SPACER 4

19 289204 SHEAVE-CHAIN 2

20 063713 SCREW-HEX HD, 1/2-13 X 2 1


22 503056 RAM HEAD 1

23 402610-04 TUBE-SPACER 1

24 051237 BEARING-THRUST 1

25 052774 SHOULDER BOLT 1

26 201319 RAM HEAD STOP 1


28 063659 SCREW-HEX HEAD, 7/16-20 X 1-1/4

2

29 060402 PIN-COTTER 4

30 402034 LIFT CHAIN, 106” LIFT TRUCK (6.04 FT) 130” LIFT TRUCK (7.06 FT) 154” LIFT TRUCK (8.09 FT) 178” LIFT TRUCK (9.13 FT) 190” LIFT TRUCK (10.16 FT) 168” LIFT TRUCK (8.68 FT)

4

31 402055 PIN-CLEVIS 2

32 402051 BOLT-CHAIN ADJUSTING 2

33 059445 NUT-HEX, 5/8-18 2


35 059545 NUT-HEX, JAM, 5/8-18 2

36 — LIFT CYLINDER (FIGURE 12-15) REF

37 191262 SPACER 1

38 250761 SPACER 1

39 100023 SPACER 1

40 401006 GUIDE BAR 1

41 064612 HEX HEAD SCREW, 3/8-16 X 2 3

42 077076 WASHER, 13/32 X 1-12 X 7GA 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-17

Figure 12-11 Lift Carriage Assembly

R6409

12-18 901270

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 059545 NUT-HEX, JAM, 5/8-18 2


3 059445 NUT-HEX, 5/8-18 2

4 402051 BOLT-CHAIN ADJUSTING 2

5 — LIFT CHAIN (FIGURE 12-10) REF

6 063705 SCREW-HEX HD, 1/2-13 X 1 2

7 077412 WASHER-LOCK, 1/2 EXT TOOTH 2

8 312801 ECCENTRIC HUB 2

9 062320 ROLLER ASSY 6

10 005936 NUT-”U” SPEED 3

11 VAR LIFT CARRIAGE 1

12 078001 WEATHERSTRIP, 33-INC LENGTH 2

13 079519 WINDOW 1


15 070478 SCREW-PH HD, 1/4-20 X 3/4 6

16 503069 DOOR AND HINGE, LH 1

17 072407 SCREW-SHT MET, #10 B X 3/4 3

18 503070 DOOR AND HINGE, RH 1

19 071376 SCREW-PH TR HD, 10-32 X 1/2 10

20 055628* SAFETY CHAIN A/R

21 074603 CONNECTING LINK 6

22 074602 SWIVEL EYE SNAP 3

23 400166 SAFETY WALK PAD 1


* SPECIFY LENGTH REQUIRED WHEN ORDERING.

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-19

Figure 12-12 Hydraulic System

R6410

12-20 901270

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 504199-05 HOSE ASSY, 3/8 1

2 025516 ELBOW-90°, SWIVEL, 3/8 NPT 1

3 048124 VALVE-RELIEF, PILOT 1

4 026116 NIPPLE-3/8 X 3, EX. HEAVY DUTY 2

5 025505 ELBOW, 90° 3/8 NPT 2

6 504199-15 HOSE ASSY-3/8 MALE PIPE 1

7 025107 COUPLING-SWVL NUT, 3/8 NPT 3

8 026707 ELBOW-STREET, 90°, 3/8 NPT 3

9 027107 TEE-PIPE, 3/8 NPT 4

10 026109 NIPPLE, HEX-3/8 NPT 5

11 038147 TUBING-NYLON, 0.375 ID X 0.50 OD (SPECIFY LENGTH)

A/R

12 025522 ELBOW-90°, 1/2 TUBE TO 3/8 NPT

2

13 048160 VALVE-RELIEF, ADJ 1

14 026114 NIPPLE, 3/8 NPT X CLOSE, HD 3

15 026152 NIPPLE-PIPE 1

16 025114 ADAPTER, FEM, 3/4 SAE X 3/8 NPT

2

17 025003 ACCUMULATOR-400 PSI 1

18 026310 PLUG-HEX, SOC, 3/8 NPT 1

19 506443 DIODE ASSY-LOWERING 1

20 055422 CONNECTOR-IN LINE 2

21 048155 VALVE-SOLENOID, 24V, REMOTE 1

22 — VALVE ASSY-LOWERING (FIG-URE 12-14)

REF

23 027120 TEE-MALE BRANCH, 3/8-18 NPT 2

24 025318 COUPLING-1/2 TUBING TO 3/8 NPT

2

25 025538 ELBOW-MALE, 90°, NPT 1

26 059429 NUT-HEX, 3/8-16 4


28 — PUMP AND MOTOR ASSY (FIGURE 12-17)

REF

29 025133 ADAPTER, HOSE, 7/8 SAE X 3/4 HOSE

1

30 056105 CABLE CLAMP 2

31 318200 HOSE-SUCTION, 3/4, NEOPRENE A/R

32 800145 NIPPLE-MACHINED 1

33 035114 FILTER 1

34 026302 PLUG-SQ HD, MAGN, 3/8 NPT 1

35 059426 NUT-HEX, 5/16-18 2

36 077210 WASHER-LOCK SPLIT, 5/16 2

37 077011 WASHER-3/8 X 7/8 X 14 GA 6

38 500422 BREATHER CAP AND DIPSTICK ASSY

1

39 506458 RESERVOIR WELDMENT 1

40 025501 ELBOW-90°, 1/4 NPT X TUBE 2

41 282500 TUBING-VINYL, 1/4 OD X 0.180 ID A/R

42 063603 SCREW-HEX HD, 3/8-16 X 3/4 4

43 056121 CLAMP, SINGLE 1

44 026504 REDUCER-PIPE, 1/2-3/8 2

45 047121 VALVE-FLOW CONTROL, 9 GPM 1

46 025513 ELBOW-45° SWVL NUT, 3/8 NPT 1

47 059416 NUT-HEX, 10-32 1

48 077407 WASHER-LOCK, #10, EXT TOOTH

1

49 069605 MACH, SCREW-PHILLIPS, FLAT HD

2

50 048111 VALVE-CHECK, 3/8 NPT PORTS 1

51 — LIFT CYLINDER (FIGURE 12-15) REF

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-21


R6411

INDEXNO.

PARTNO. PART NAME

NO.REQD.

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


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

4 077209 WASHER-LOCK, SPLIT 1/4 4

5 074270 SHEAVE-STEERING 4


7 051223 BEARING THRUST 4

8 — VALVE ASSY-LOWERING (FIGURE 12-12)

REF

9 077031 WASHER-5/16 X 3/4 X 16 GA 2

10 060403 PIN-COTTER, 1/16 DIA X 1/2LG 1

11 402976 LINK-CONNECTING, VALVE 1

12 060319 PIN-CLEVIS, 1/4 X 3/4 1

13 059526 NUT-HEX, JAM, 5/16-18 2

14 402977 WASHER-SPRING 1

15 075089 SPRING-COMPRESSION 1

16 402864 ROD-ADJUSTMENT. LOWER 1

17 053307 CABLE 3/16,7 X 19 GALVANIZED 106” LIFT TRUCK (200 FT)130” LIFT TRUCK (224 FT)154” LIFT TRUCK (248 FT)178” LIFT TRUCK (272 FT)190” LIFT TRUCK (284 FT)168” LIFT TRUCK (262 FT)

1

18 506341 BRACKET 1

19 059429 NUT-HEX, 3/8-16 3

20 072407 SCREW-SHT MET, #10B X 3/4 2

21 060417 PIN-COTTER, 3/32 DIA X 3/4 LG 1

22 077011 WASHER-3/8 X 7/8 X 14 GA 4

23 057962 KNOB-ROUND, 3/8-16 1

24 503226 LEVER WLDMT-ARM 1

25 060300 PIN-CLEVIS, 5/16 DIA X 31/32 1

26 505039 HOLDER WELDM’T-CABLE 1

27 059430 NUT-HEX, 3/8-24, R.H. THREADED

1

28 076213 TURNBUCKLE 1

29 059431 NUT-HEX, 3/8-24, LEFT HAND THD

1


31 075627 END-CABLE, STUD, LH 1

32 503225 BRACKET WLDMT 1

33 059936 NUT-SPEED, U-TYPE 1

34 059930 NUT-SPEED, #10 A 1

35 061709 RING-SNAP, EXT., 3/8 DIA 1

36 056560 DECAL-LOWER 1

37 — RAM HEAD (FIGURE 12-10) REF

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-22 901270

Figure 12-14 Throttle Valve Assembly

R6334

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 503050 VALVE ASSY-LOWERING 1

1 075052 . SPRING-COMPRESSION 1

2 051404 . BALL-STEEL, 3/8 CHROME, GR 1000

1

3 060608 . ROLLER-NEEDLE, 0.1562 DIA X 1.25LG

1

4 026314 . PLUG-HEX SOC, 1/4 NPT, FLUSH

1

5 060940 . PIN-ROLL, 1/8 DIA X 1 LG 1

6 161298 . ARM-ACTUATING 1

7 245763 . PLATE-VALVE THROTTLE 1

8 070475 . SCREW-PH RD HD, 1/4-20 X 3/8

1

9 304611 . CAM-RELEASE, VALVE 1

10 042104 . O-RING-9/16 ID X 3/4 OD 1

11 240501 . BODY-VALVE, THROTTLE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-23

Figure 12-15 Lift Cylinder

R6412

1

6

7

11

2

3

4

510

8

9

PACKING KIT PART NUMBER

907181 CONTAINS:

ITEM QTY2 14 17 18 1

10 111 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505095-01 LIFT CYLINDER (106” LIFT) 1






1 — . TUBE 1

2 —* . WIPER RING 1

3 901759 . GLAND NUT 1

4 —* . O-RING PACKING 1

5 — . RAM STOP 1

6 VAR . RAM ROD 1

7 —* . O-RING 1

8 —* . PISTON SEAL 1

9 — . PISTION 1

10 —* . WEAR RING 1

11 —* . NUT 1

* 907181 PACKING KIT INCLUDES ITEMS 2, 4, 7, 8, 10 AND 11

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-24 901270

NOTES

901270 12-25


R6419

A

P

B+

B-

CB

A

R

S

FWD

CNTCR

REV CNTCR

A

APUMP CNTCTR

CNTCTR

BYPASS

VIEW A-A

123

4

121

3736

19

13

5

6

78

910

1112

3334

35

1

13

214

1516

17

18

19

2021

14

22

2928

27

26

30

27

31

32

3534



2324

25

12-26 901270

0

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 059421 NUT-HEX, 1/4-20 4


3 005996 DIODE ASSY-400V, 1A 1

4 009602 HORN-24V, W/BRACKET 1

5 069483 SCREW-PH FL HD, 1/4-20 X 1-1/2 2

6 057508 GROMMET-RUBBER, 1-3/8 DIA X 7GA

1

7 005401 CONNECTOR-BATT, 175 AMP (GRAY)

1

8 068480 MACH. SCREW-SLOTTED, ROUND HD

2

9 20574 DECAL-PUSH TO ENERGIZE 1

10 069465 SCREW-SL FL HD, #6-32 X 5/8”LG 2

11 074712 SPACER-NYLON, #6 X 0.25LG 2

12 020697 SWITCH-PUSHBUTTON, BLACK 1

13 — CABLE-CONTROL, FLEX, 18GA-12COND (FIGURE 12-1)

REF

14 077031 WASHER-5/16 X 3/4 X 16 GA 5

15 404908 BRACKET-CONNECTOR, HARNESS

1

16 023294 HARNESS ASSY-CONTROL, CONTACTOR

1



19 — ELECTRICAL CONTROL CABLE (FIGURE 12-3)

A/R

20 063480 SCREW-HEX HD, 1/4-20 X 1 3


22 — CONTACTOR PANEL ASSY (FIGURE 12-20)

REF

23 — PANEL ASSY-EPD (FIGURE 12-21)

REF


25 059429 NUT-HEX, 3/8-16 3

26 503965-35 CABLE ASSY (PUMP POS) 1

27 503965-59 CABLE ASSY (F2) 2

28 503965-76 (PUMP NEG) 1

29 — CABLE ASSY (BATTERY NEG) REF

30 — CABLE ASSY (BATTERY POS) REF

31 503965-35 CABLE ASSY (A1) 1

32 503965-35 CABLE ASSY (F1) 1

33 056141 CLAMP-CABLE 2


35 059426 NUT-HEX, 5/16-18 2

36 056120 DOUBLE CLAMP 1


INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-27

Figure 12-17 Hydraulic Pump and Motor Assembly

R6413

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 016929 PUMP & MOTOR ASSY 1

1 — . PUMP MOTOR (FIGURE 12-18) REF

2 — . DRIVE CONNECTOR 1

3 036107 . GASKET, PUMP TO MOTOR 1

4 904155 . PUMP 1

5 077210 . WASHER-LOCK, SPLIT, 5/16 4

6 063557 . SCREW-HEX HD, 5/16-18 X 1-1/4 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-28 901270

Figure 12-18 24V Hydraulic Pump Motor Assembly

R6343

KIT PART NUMBER 905062 CONTAINS:

ITEM QTY6 17 18 19 1

10 111 112 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 905053 PUMP MOTOR ASSY 1

1 905055 . BAND COVER 1

2 — . . SCREW, RD HD 10-32 X 1-3/4 1

3 — . . NUT, SQUARE 10-32 1

4 905056 . SCREW, HEX HDTHD ROLLING 10-32 X 2

4

5 905057 . BOLT, SQUARE NECK, 10-32 X 7/8

4

6 —* . NUT, HEX 10-32 4

7 —* . LOCK WASHER, #10 4

8 905058* . HEAD, COMMUTATOR END 4

9 —* . SCREW, ROUNDD HEAD1/4-20 X 3/8

1

10 905059* . BRUSH SET, SERVICE 1

11 905060* . BRUSH HOLDER PLATE 1

12 905061* . SPRING SET, BRUSH 1

13 905063 . TERMINAL STUD PACKAGE 1

14 905064 . FIELD COIL, INCLUDES HARDWARE

1

15 905065 . SPRING WASHER 1

16 905066 . BEARING, COMMUTATOR END 1

17 905067 . ARMATURE & FAN ASSY 1

18 — . SCREW, FILLISTER HEAD, 10-32 X 3/4

8

19 905068 . BEARING, DRIVE END 1

20 905069 . HEAD, DRIVE END 1

* INCLUDED IN KIT 905062

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-29

Figure 12-19 Drive Motor Assembly

R6422

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 016056 MOTOR ASSY 1

1 903283 . DRIVE END HEAD 1

2 — . FRAME & FIELD ASSEMBLY 1

3 — . ARMATURE ASSEMBLY 1

4 903258 . BRUSH BOX ASSEMBLY 1

5 903262 . BRUSH SET 1

6 903260 . BRUSH SPRING SET 1

7 903265 . BRUSH LEAD & TERMINALSERVICE KIT

1

8 903266 . RETAINING RING 1

9 903263 . BEARING 1

10 903284 . COMMUTATOR HEAD 1

11 903285 . HEADBAND ASSEMBLY 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-30 901270

Figure 12-20 Electrical Control Panel

R6420

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 005674 CONTACTOR PANEL ASSEMBLY 1

1 130-14326 . BASEPLATE 1

2 632T46231 . FLASH PPK MED IO 48V 650A 1

3 677-11099 . BASEPLATE SUB ASSY 1

4 — . CABLE ASSY-BNEG 1

5 — . CABLE ASSY-POINT A 1

6 — . CABLE ASSY-BPOS 1

7 184-22009 . HARNESS-PANEL 1

8 662-13135 . MODULE-PST 1

9 803-36001 . TWIN-STICK PAD (NOT SHOWN) 5

10 828-37023 . CONT., SW200, 24V, INTERMITTENT

2

11 828-37407 . CONT., SW202, 24V, INTERMITTENT

1

12 121-50543 . LINK COPPER 1

13 121-50540 . LINK (650A TERMINAL S) 1

14 501-12506 . SCREW-HX HD, 5M X 10MM LG 8

15 572-12305 . WASHER-SPRING, ST. ZP, 5M 10

16 501-12610 . SCREW-HX HD, ST. ZP., 6M X 20MM, LG

4

17 572-12306 . WASHER-SPRING, ST. ZP, 6M 4

18 570-50506 . WASHER-FLAT, ST. ZP., 6M 6

19 501-12607 . SCREW-HX HD, ST. ZP., 6M X 12MM, LG

2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-31

Figure 12-21 EPD Panel

R6421

MAX. 300 A

DELAY TYP

1

2

3

24

23

22

21 2019,20

15,16,17

11

12

25

9,10

87264,5,6

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 506459 EPD PANEL ASSY 1

1 404907 . PANEL-EPD 1

2 018409-02 . RELAY-FLANGE MOUNT, 24V 1

3 506461 . DIODE ASSY-RELAY 1

4 068235 . SCREW-RH HD, #6-32 X 1/2 2

5 077204 . WASHER-LOCK, SPLIT, #6 2

6 077007 . WASHER-FLAT, #6 2

7 005669-02 . CONTACTOR-24V 1

8 506460 . DIODE ASSY-EPD CONTACTOR 1

9 071379 . SCREW-PH TR HD, #10-32 X 1/4 4

10 077207 . WASHER-LOCK, SPLIT, #10 4

11 504277-23 . CABLE ASSY-#2 AWG, BATT POS

1

12 504277-22 . CABLE ASSY-#2 AWG, BATT NEG

1

13 — . NOT USED

14 — . NOT USED

15 070489 . SCREW-RD HD, 1/4-20 X 5/8 BRASS

3

16 077209 . WASHER-LOCK, SPLIT, 1/4” 3

17 077105 . WASHER-FLAT, 1/4” BRASS 3

18 010614 . STANDOFF 3

19 075623-01 . STUD-PRESS-IN, 1/4-20 X 1/2 3

20 056507 . DECAL-FUSE, 300 AMP 1

21 008906 . FUSE-300 AMP 1

22 503965-89 . CABLE ASSY-#2 AWG 1

23 008917 . FUSE-40 AMP 1

24 056515 . DECAL-FUSE, 40 AMP 1

25 503965-77 . CABLE ASSY-#2 AWG 1

26 023238-31 . WIRE ASSY 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-32 901270

Figure 12-22 Flashing Red Light Figure 12-23 Warning Light Stand

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 013611-01 LIGHT-WARNING,FLASHING, RED 1

1 013611-03 LIGHT-WARNING,STROBE, RED 1

— 904823 . BULB FLASHING-LIGHT FLASHING

1

— 904824 . BULB STROBE-LIGHT STROBE

1

— 904826 . LENSE, RED 1

2 071377 SCREW-PH TR HD, #10-32 X 3/4 3

3 056621 GUARD, LIGHT 1

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


6 077030 WASHER-1/4 X 9/16 X 16 GA 2

7 057510 GROMMET-RUBBER, 3/8 X 5/8, 1/4 TH

1

8 059416 NUT-HEX, #10-32 3


R5804

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 — LIGHT-WARNING, (FIGURE 12-22) REF

2 — GROMMET (FIGURE 12-22) REF

3 — ACCESS COVER (FIGURE 12-6) REF


5 063477 SCREW-HEX HD, 1/4-20 X 5/8 2

6 505819 STAND-WARNING LIGHT 1

R6439

901270 12-33

Figure 12-24 Optional Lift Limit

INDEX NO.

PART NO.

PART NAMENO.

REQD.WITH

OVERRIDEWITHOUT

OVERRIDE

1 062918 — HEX SOCKET CAP SCREW 2

2 056557 — DECAL, LIF-LIM OVR/RID 1

3 074712 — SPACER-NYLON, #6 X 0.25 LG 2

4 020697 — SWITCH-PUSHBUTTON, BLACK 1

5 021204 — TERMINAL-SLIP ON, 1/4 2

6 023018 — WIRE-16 GA, BLACK A/R

7 021203 — TERMINAL-RING, 3/16, 16 GA 1

8 004723 004724 HARNESS 1

9 021203 021203 TERMINAL-RING, 3/16, 16 GA 1

10 005433 005433 CONNECGTOR-SPLICE, INLINE 1

11 005405 005405 RELIEF-STRAIN, 3/8 1

12 020703 020703 SWITCH-LIMIT 1

13 021210 — TERMINAL-FORK, INSUL, #6,14 - 16 GA 3

13 — 021210 TERMINAL-FORK, INSUL, #6,14 - 16 GA 2

1

(W/O OVERRIDE)

TO OVERRIDE

(W/ OVERRIDE)

LIFT

LIMIT

OVERRIDE

12

3

4

56

7

8

9

9

10

8

111213

R6440

12-34 901270

Figure 12-25 Optional Type YC Battery & Changer Connectors

R6442

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 005404 PLUG ASSY-CONNECTOR, YC 1

2 005400 RECEPTACLE-CONN, YC 2

3 063483 SCREW-HEX HD, 1/4-20 X 1-3/4 3

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-35

Figure 12-26 Optional Type EC Battery & Changer Connectors

R6443

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 005419 CONNECTOR-BATTERY, EC 1

2 005418 CONNECTOR ASSY-CHARGER, EC

1

3 005420 CONNECTOR ASSY-MOUNTING, EC

1


5 063478 SCREW-HEX HD, 1/4-20 X 3/4 4

6 056111 TIE, WIRE, NYLON, SMALL 10

7 283700 CABLE-WELDING, #2 AWG, 62” 2

8 057508 GROMMET-RUBBER, 1-3/8 DIA X 7GA

1

9 070476 SCREW-PH RH HD, 1/4-20 X 1/2 1


11 056130 CLAMP-CABLE, 3/4” 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-36 901270

Figure 12-27 Optional Type N Battery & Changer Connectors

R6444

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 005431 CONNECTOR-BATTERY, TYPE N 1

2 005430 CONNECTOR-CHARGER, TYPE N

1

3 005425 CONNECTOR-BATTERY, TYPE N, 100A

1


5 063478 SCREW-HEX HD, 1/4-20 X 3/4 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-37

Figure 12-28 Optional Travel Cutout

R6441

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 005405 RELIEF-STRAIN, 3/8 1

2 020703 SWITCH-LIMIT 1

3 021210 TERMINAL-FORK, INSUL, #6,14-16 GA

3

4 005433 CONNECTOR-SPLICE, INLINE 1

5 004724 CORD-2 COND, 16 GA A/R0

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-38 901270

NOTES

901270 12-39

Figure 12-29 Pallet Clamp

R6361

12-40 901270

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 503163 PALLET CLAMP INSTL 1

1 503158 . BRACKET WLDMT 1

2 070476 . SCREW-PH RD HD, 1/4-20 X 1/2 3

3 503157 . HANDLE WLDMT 1

4 057952 . KNOB, BLACK, 3/8-16 1

5 077034 . WASHER-1/2 X 0.844 X 16 GA 7

6 503178 . CABLE ASSY-PALLET CLAMP 1

7 073474 . SCREW-SET, 1/4-20 X 1/4” LG 1

8 201343 . BAR-PIVOT 1


10 061713 . RING-SNAP, EXT., 1/2” DIA 5

11 061719 . RING-SNAP, EXT., 3/4: DIA 3

12 077010 . WASHER, 0.765 X 1.500 X 14 GA 4

13 503162 . PLATE & TUBE WLDMT 2

14 064712 . SCREW-HEX, 1/2-13 X 5” LG 4

15 400028 . PLATE-RECT 1

16 400018 . BRACKET-SHEAVE 1

17 063821 . SCREW-HEX HD, 5/8-11 X 1-3/4 1

18 074267 . SHEAVE & BEARING ASSEMBLY 1

19 077096 . WASHER, 1-1/8 X 5/8 X 16 GA 1


21 059444 . NUT, HEX, 5/8-11 1

22 075068 . SPRING-EXTENSION 1

23 400026 . PIN-PIVOT 1

24 314338 . SPACER-TUBE 1

25 400029 . PLATE-RECT 1

26 503118 . ARM-RH, PALLET CLAMP 1

27 075067 . CLAMP PRESSURE SPRING 1

28 503119 . ARM-LH, PALLET CLAMP 1

29 503165 . PLATE & PIN WLDMT 1

30 077036 . WASHER A/R

31 059437 . NUT-HEX, 1/2-13 4


INDEXNO.

PARTNO. PART NAME

NO.REQD.

901270 12-41

Figure 12-30 Optional Slip On Platform

R2103

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 503502-01 PLATFORM-36 x 36 1

1 503502-02 PLATFORM-36 x 42 1

1 503502-03 PLATFORM-36 x 48 1

2 055628 CHAIN-3/16 DIS. (SPECIFY LENGTH)

A/R

3 0774602 MICRO-WASHER 1-3/8”O.D. X 3/4”I.D.

3

4 074603 COLD SHUT 6

5 063715 SCREW-HEX HD, 1/2-13 X 2-1/4” 2

6 077104 WASHER-FLAT, STANDARD, 1/2” 4

7 059639 NUT-LOCK, HEX, 1/2-13 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-42 901270

Figure 12-31 Safety Harness & Lanyard Figure 12-32 Safety Belt

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 074006 LANYARD-6’ 1

2 074010 HARNESS 1

R6418

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 055628 SAFETY CHAIN (2 FT EA) 2

2 074603 CONNECTING LINK 4

3 074602 SWIVEL EYE SNAP 2

4 074002 SAFETY BELT 1

R6438

901270 12-43

Figure 12-33 Side Guide Roller (Steel)

Figure 12-34 Side Guide Roller (Polyurethane)

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 260603 STEEL ROLLERS 4

2 272803 CENTER MOUNT 4

3 069710 SOCKET HEAD SCREW, 1/5-13 X 1-3/4

3

4 — BASE SLIDE BAR 2

5 — STRADDLE SLIDE BAR 2

6 073460 SET SCREW, 10-24 X 1/4 4

R6358

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 061725 RETAINING RING 4

2 050703 AXLE 4

3 077033 SPACER 8

— 078518 WHEEL ASSSEMBLY (5 IN DIA) 4

4 051136 . BEARING 1

5 078561 . WHEEL 1

6 060976 ROLL PIN, 3/16 X 1-1/2 4

7 — HOUSING (1 RH, 1 LH) 2

R6363

12-44 901270

Big Joe Manufacturing Company

Documents

SSC Series - Big Lift, LLC Support Site for Big Joe … · Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901270 Rev C 07/28/2006 SSC Series TELESCOPIC STOCK SELECTOR,