Manual: 900980

Model: SSCM
Serial Number: 334774 and higher

This manual is effected by the following supplements. They can be found in the Service
Manual Index CD on the left side of the screen under "Supplements To Manuals."

SUPPLEMENT TITLE
245 BATTERY SAFETY AND MAINTENANCE
324 SSCM PIVOT TUBE SUPPLEMENT
326 SSCM EPD RETROFIT KIT
331 TANK FILTER SUPPLEMENT
335 A BATTERY CHARGER 004978 TROUBLESHOOTING GUIDE
339 PUMP AND MOTOR 016940
352 SSCM TRANS/CONTROLLER/CONTACTOR TYPE E
356 CYLINDER 503568 PACKING CHANGE
 SSCM Series
STOCK SELECTOR
COUNTERBALANCED
LIFT TRUCK
Serial Number 334774 to 374072
Operation
Maintenance
Repair Parts List

Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 900980
Rev B 07/27/2007
 TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 4-3.3. CHECK FOR POWER TO THE
1-1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 1-1 CONTROLLER. . . . . . . . . . . . . . . . . . . . . . 4-5
1-2. GENERAL DESCRIPTION. . . . . . . . . . . . . 1-1 4-3.4. CHECK FOR CONTACTOR OPERATION
1-2.1. WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 AND KEYSWITCH INPUT (KSI). . . . . . . . . 4-5
1-3. SAFETY FEATURES. . . . . . . . . . . . . . . . . 1-2 4-3.5. CHECK POTENTIOMETER CIRCUITRY. . 4-6
1-4. OPTIONS AND ACCESSORIES. . . . . . . . . 1-2 4-3.6. CHECK FOR CONTROLLER OUTPUT.. . . 4-6
1-5. SAFETY SYMBOLS. . . . . . . . . . . . . . . . . . 1-2 4-4. ADJUSTMENT OF CONTROLLER
POTENTIOMETERS. . . . . . . . . . . . . . . . . . 4-7
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
4-5. EPD TROUBLESHOOTING . . . . . . . . . . . 4-8
2-1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
4-5.1. EMERGENCY POWER DISCONNECT
2-2. OPERATING PRECAUTIONS.. . . . . . . . . . 2-1
CIRCUIT OPERATION . . . . . . . . . . . . . . . . 4-8
2-3. BEFORE OPERATION. . . . . . . . . . . . . . . . 2-2
4-5.2. TROUBLESHOOTING PROCEDURE . . . . 4-8
2-4. INSTRUMENTS AND CONTROLS . . . . . . 2-4
4-6. SMART CHARGER 004978
2-5. OPERATION . . . . . . . . . . . . . . . . . . . . . . . 2-4
TROUBLESHOOTIN. . . . . . . . . . . . . . . . . 4-12
2-5.1. DRIVING AND STOPPING
PROCEDURES . . . . . . . . . . . . . . . . . . . . . 2-4 5 STEERING SYSTEM MAINTENANCE . . . . . . . . . . 5-1
2-5.2. BRAKING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 5-1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
2-5.3. OPERATING LIFT . . . . . . . . . . . . . . . . . . . 2-5 5-2. STEERING CABLE TENSION. . . . . . . . . . . 5-1
2-5.4. EMERGENCY LOWERING . . . . . . . . . . . . 2-5 5-3. STEERING SHEAVE AND PIVOT
2-5.5. EMERGENCY POWER DISCONNECT . . . 2-6 BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . 5-7
2-5.6. PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 5-4. SHEAVE ASSEMBLIES.. . . . . . . . . . . . . . . 5-8
2-5.7. BATTERY CHARGING. . . . . . . . . . . . . . . . 2-6 5-5. STEERING CABLE REPLACEMENT. . . . . 5-9
2-5.8. LOAD HANDLING. . . . . . . . . . . . . . . . . . . . 2-6 5-5.1. PRELIMINARY PREPARATION. . . . . . . . . 5-9
2-5.9. PALLET CLAMP . . . . . . . . . . . . . . . . . . . . . 2-6 5-5.2. REPLACING LOWER STEERING CABLE. 5-9
2-5.10. MOVING A DISABLED TRUCK . . . . . . . . . 2-6 5-5.3. REPLACING UPPER STEERING CABLE.. 5-9
5-5.4. ATTACHING SOCKET ASSEMBLIES TO
3 PLANNED MAINTENANCE . . . . . . . . . . . . . . . . . . . 3-1
WIRE ROPE. . . . . . . . . . . . . . . . . . . . . . . 5-10
3-1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
5-5.5. CONCLUDING STEPS. . . . . . . . . . . . . . . 5-10
3-2. PERIODIC CHECKS. . . . . . . . . . . . . . . . . . 3-1
5-6. PIVOT TUBE REPLACEMENT. . . . . . . . . 5-11
3-3. BATTERY CARE. . . . . . . . . . . . . . . . . . . . . 3-1
5-6.1. REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . 5-11
3-3.1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
5-6.2. INSTALLATION. . . . . . . . . . . . . . . . . . . . . 5-11
3-3.2. BATTERY SERVICING. . . . . . . . . . . . . . . . 3-2
3-4. LUBRICATION. . . . . . . . . . . . . . . . . . . . . . 3-2 6 BRAKE SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . 6-1
3-5. LIFT CHAIN MAINTENANCE. . . . . . . . . . . 3-2 6-1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. BRAKE DEADMAN SWITCH . . . . . . . . . . . 6-1
4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 4-1
6-3. BLEEDING THE BRAKE SYSTEM. . . . . . . 6-1
4-1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
6-4. BRAKE HOSE REPLACEMENT. . . . . . . . . 6-1
4-2. CIRCUIT OPERATION . . . . . . . . . . . . . . . . 4-1
6-5. BRAKE ADJUSTMENT. . . . . . . . . . . . . . . . 6-1
4-2.1. SMOOTH STEPLESS OPERATION. . . . . . 4-3
6-6. REPLACEMENT OF DISC BRAKE PARTS 6-4
4-2.2. CURRENT MULTIPLICATION. . . . . . . . . . 4-3
4-2.3. ACCELERATION LIMITING. . . . . . . . . . . . 4-3 7 TRANSMISSION, DRIVE WHEEL, AND LOAD
4-2.4. CURRENT LIMITING. . . . . . . . . . . . . . . . . 4-3 WHEEL SERVICING . . . . . . . . . . . . . . . . . . . . . . . . 7-1
4-2.5. PLUGGING. . . . . . . . . . . . . . . . . . . . . . . . . 4-3 7-1. TRANSMISSION REMOVAL . . . . . . . . . . . 7-1
4-2.6. UNDERVOLTAGE PROTECTION . . . . . . . 4-4 7-2. TRANSMISSION REPAIR . . . . . . . . . . . . . 7-2
4-2.7. OVERVOLTAGE PROTECTION. . . . . . . . . 4-4 7-3. TRANSMISSION INSTALLATION . . . . . . . 7-3
4-2.8. THERMAL PROTECTION. . . . . . . . . . . . . . 4-4 7-4. DRIVE WHEEL REPLACEMENT . . . . . . . . 7-3
4-2.9. ACCELERATOR FAULT PROTECTION 7-5. LOAD WHEEL REPLACEMENT . . . . . . . . 7-4
(RUNAWAY PROTECTION). . . . . . . . . . . . 4-4
8 ELEVATION SYSTEM SERVICING. . . . . . . . . . . . . 8-1
4-2.10. CONTROLLER FAULT PROTECTION. . . . 4-4
8-1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
4-2.11. WEATHER RESISTANCE.. . . . . . . . . . . . . 4-4
8-2. RAM HEAD REPLACEMENT . . . . . . . . . . . 8-1
4-2.12. ARCLESS F/R SWITCHING. . . . . . . . . . . . 4-4
8-3. LIFT CHAIN ADJUSTMENT . . . . . . . . . . . . 8-1
4-2.13. HIGH PEDAL DISABLE (HPD). . . . . . . . . . 4-4
8-4. LIFT CHAIN WEAR INSPECTION . . . . . . . 8-4
4-3. CONTROLLER TROUBLESHOOTING . . . 4-5
8-5. LIFT CHAIN REPLACEMENT . . . . . . . . . . 8-4
4-3.1. TOOLS REQUIRED . . . . . . . . . . . . . . . . . . 4-5
8-6. LIFT CYLINDER REPLACEMENT . . . . . . . 8-5
4-3.2. PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 4-5
8-7. LIFT CARRIAGE REMOVAL . . . . . . . . . . . 8-5
8-8. LIFT CARRIAGE DISASSEMBLY . . . . . . . 8-6

900980 i
 TABLE OF CONTENTS (Continued)

Section Page Section Page

8-9. INNER MAST REMOVAL (SSCM 20-130) 8-6 10-3.3. PANEL DISASSEMBLY AND
8-10. MAST LUBRICATION PROCEDURE . . . . 8-6 REASSEMBLY. . . . . . . . . . . . . . . . . . . . . 10-4
8-11. BASE AND FRAME . . . . . . . . . . . . . . . . . . 8-6 10-3.4. CONTACTOR DISASSEMBLY. . . . . . . . . 10-9
10-3.5. CONTACTOR REASSEMBLY. . . . . . . . 10-10
9 HYDRAULIC SYSTEM SERVICING . . . . . . . . . . . . 9-1
10-4. PUMP MOTORS. . . . . . . . . . . . . . . . . . . 10-10
9-1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10-5. DRIVE MOTORS.. . . . . . . . . . . . . . . . . . 10-10
9-2. RELIEVING SYSTEM PRESSURE. . . . . . 9-1
10-6. BATTERIES.. . . . . . . . . . . . . . . . . . . . . . 10-10
9-3. HYDRAULIC PRESSURE ADJUSTMENT. 9-2
10-7. HIGH SPEED LIMIT SWITCH. . . . . . . . . 10-10
9-4. LINE, FITTING AND HOSE
10-7.1. OPERATIONAL CHECK . . . . . . . . . . . . 10-10
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . 9-3
10-7.2. ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 10-11
9-5. SUMP FILTER REPLACEMENT. . . . . . . . 9-3
10-7.3. REPLACEMENT. . . . . . . . . . . . . . . . . . . 10-11
9-6. HANG-UP VALVE REPLACEMENT. . . . . . 9-3
10-8. BATTERY CHARGERS.. . . . . . . . . . . . . 10-11
9-7. HYDRAULIC PUMP AND MOTOR
10-9. EPD CONTACTOR ASSEMBLY. . . . . . . 10-12
ASSEMBLY.. . . . . . . . . . . . . . . . . . . . . . . . 9-4
10-9.1. ASSEMBLY REPLACEMENT
9-8. LIFT CYLINDER REPAIR. . . . . . . . . . . . . . 9-6
(TRUCKS SERIAL NUMBER
9-9. MANUAL LOWERING COMPONENTS. . . 9-8
356021 TO 374092). . . . . . . . . . . . . . . . 10-12
10 ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . 10-1 10-9.2. EPD CONTACTOR ASSEMBLY -
10-1. DIRECTIONAL SWITCH.. . . . . . . . . . . . . 10-1 (ASSEMBLY/DISASSEMBLY) . . . . . . . . 10-12
10-1.1. REMOVAL.. . . . . . . . . . . . . . . . . . . . . . . . 10-1 10-10. EPD CONTACTOR REPAIR . . . . . . . . . 10-12
10-1.2. DISASSEMBLY FOR TRUCKS SERIAL
11 OPPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . 11-1
NUMBERS 334774 TO 351122. . . . . . . . 10-1
11-1. HOUR METER . . . . . . . . . . . . . . . . . . . . . 11-1
10-1.3. DISASSEMBLY FOR TRUCKS SERIAL
11-2. BATTERY CAPACITY INDICATOR. . . . . 11-1
NUMBERS 351123 TO 374092. . . . . . . . 10-2
11-3. LIFT LIMIT AND LIFT LIMIT OVERRIDE. 11-1
10-2. ELECTRICAL CABLE MAINTENANCE. . 10-2
11-4. FLASHING RED LIGHT. . . . . . . . . . . . . . 11-1
10-2.1. TENSION ADJUSTMENT. . . . . . . . . . . . . 10-2
11-5. SIDE GUIDE ROLLERS. . . . . . . . . . . . . . 11-1
10-2.2. REPLACEMENT. . . . . . . . . . . . . . . . . . . . 10-3
11-6. OPERATOR SAFETY HARNESS AND
10-3. ELECTRICAL CONTROL PANEL.. . . . . . 10-4
BELTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
10-3.1. ADJUSTMENT OF CONTROLLER
11-7. SLIP ON PLATFORM. . . . . . . . . . . . . . . . 11-1
POTENTIOMETERS.. . . . . . . . . . . . . . . . 10-4
11-8. BATTERY QUICK DISCONNECT
10-3.2. PANEL REPLACEMENT. . . . . . . . . . . . . 10-4
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12 ILLUSTRATED PARTS BREAKDOWN . . . . . . . . . 12-1

LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 NAME PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 4-11 WIRING DIAGRAM (SHEET 1 OF 2) . . . . . . . . 4-22
2-1 LOAD CENTER. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 5-1 STEERING CABLE DIAGRAM . . . . . . . . . . . . . . 5-2
2-2 SAMPLE OF OPERATOR CHECK LIST . . . . . . 2-3 5-2 STEERING CABLE DIAGRAM . . . . . . . . . . . . . . 5-3
2-3 OPERATOR’S CONTROLS . . . . . . . . . . . . . . . . 2-5 5-3 STEERING CONTROLS (SHEET 1 OF 3) . . . . . 5-4
3-1 LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . 3-3 5-4 STEERING SHEAVE AND PIVOT BUSHINGS . 5-7
4-1 FULL FEATURE ELECTRONIC MOTOR 5-5 STEERING SHEAVE AND PIVOT BUSHINGS . 5-8
CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 5-6 ASSEMBLY OF STEERING CABLES. . . . . . . . 5-10
4-2 LOCATION OF ADJUSTMENT POTS . . . . . . . . 4-7 5-7 TRANSMISSION, BRAKE AND MOTOR
4-3 SIMPLIFIED EMERGENCY POWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
DISCONNECT CIRCUIT. . . . . . . . . . . . . . . . . . . 4-9 5-8 TRANSMISSION, BRAKE AND PIVOT TUBE
4-4 EMERGENCY POWER DISCONNECT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
TROUBLESHOOTING CHART. . . . . . . . . . . . . 4-10 6-1 TRANSMISSION, BRAKE AND MOTOR
4-5 BATTERY CHARGER SCHEMATIC . . . . . . . . 4-12 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
4-6 LOGIC BOARD JUMPER POSITION . . . . . . . . 4-12 6-2 TRANSMISSION, BRAKE AND PIVOT TUBE
4-7 LOGIC FLOW DIAGRAM (SHEET 1 OF 2) . . . 4-14 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
4-8 ELECTRICAL SCHEMATIC (SHEET 1 OF 2) . 4-16 6-3 CHASSIS BRAKE COMPONENTS. . . . . . . . . . . 6-4
4-9 ELECTRICAL SCHEMATIC (SHEET 1 OF 2) . 4-18 7-1 CHASSIS BRAKE COMPONENTS. . . . . . . . . . . 7-1
4-10 WIRING DIAGRAM (SHEET 1 OF 2) . . . . . . . . 4-20 7-2 CHASSIS BRAKE COMPONENTS. . . . . . . . . . . 7-2

ii 900980
 LIST OF ILLUSTRATIONS (Continued)

Figure Page Figure Page

7-3 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 12-16 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . 12-30
7-4 LOAD WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 12-17 CARRIAGE MOUNTED ELECTRICAL
8-1 ELEVATION SYSTEM (SSCM 20-67). . . . . . . . . 8-2 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 12-32
8-2 ELEVATION SYSTEM (SSCM 20-130). . . . . . . . 8-3 12-18 CHASSIS MOUNTED ELECTRICAL
8-3 LIFT CARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 12-34
8-4 BASE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . 8-7 12-19 CHASSIS MOUNTED ELECTRICAL
9-1 HYDRAULIC SCHEMATIC DRAWING . . . . . . . . 9-1 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 12-36
9-2 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 9-2 12-20 CONTROL CABLE. . . . . . . . . . . . . . . . . . . . . 12-38
9-3 HYDRAULIC PUMP AND MOTOR ASSEMBLY . 9-4 2-21 DIRECTIONAL SWITCH ASSEMBLY . . . . . . 12-39
9-4 LIFT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . 9-7 12-22 DIRECTIONAL SWITCH ASSEMBLY . . . . . . 12-40
9-5 CARRIAGE OPERATED MANUAL LOWERING 12-23 HYDRAULIC PUMP AND MOTOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 12-41
10-1 DIRECTIONAL SWITCH ASSEMBLY . . . . . . . . 10-1 12-24 MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . 12-42
10-2 DIRECTIONAL SWITCH ASSEMBLY . . . . . . . . 10-2 12-25 HYDRAULIC PUMP AND MOTOR
10-3 CONTROL CABLE ADJUSTMENT . . . . . . . . . . 10-3 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
10-4 CARRIAGE MOUNTED ELECTRICAL 12-26 HYDRAULIC PUMP AND MOTOR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44
10-5 CHASSIS MOUNTED ELECTRICAL 12-27 DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . 12-45
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 12-28 CONTACTOR PANEL ASSEMBLY . . . . . . . . 12-46
10-6 CHASSIS MOUNTED ELECTRICAL 12-29 EPD CONTACTOR ASSEMBLY . . . . . . . . . . 12-48
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 12-30 DOUBLE POLE CONTACTOR . . . . . . . . . . . 12-50
10-7 CONTACTOR PANEL ASSEMBLY. . . . . . . . . . 10-8 12-31 400 AMP CONTACTOR SERVICE KIT . . . . . 12-52
10-8 DOUBLE POLE CONTACTOR . . . . . . . . . . . . . 10-9 12-32 TIMER CHARGER INSTALLATION . . . . . . . 12-54
10-9 EPD CONTACTOR ASSEMBLY . . . . . . . . . . . 10-12 12-33 TIMER CHARGER . . . . . . . . . . . . . . . . . . . . . 12-55
10-10 400 AMP CONTACTOR SERVICE KIT. . . . . . 10-13 12-34 AUTO CHARGER 120 VAC. . . . . . . . . . . . . . 12-56
11-1 OPERATOR SAFETY BELT . . . . . . . . . . . . . . . 11-1 12-35 AUTO CHARGER 004978 AND 004980 . . . . 12-57
12-1 STEERING CONTROLS (SHEET 1 OF 3) . . . . 12-2 12-36 OPTIONAL LIFT LIMIT OVERRIDE . . . . . . . 12-58
12-2 STEERING SHEAVE AND PIVOT BUSHING . . 12-6 12-37 OPTIONAL HOUR METER . . . . . . . . . . . . . . 12-59
12-3 STEERING SHEAVE AND PIVOT BUSHING . . 12-7 12-38 OPTIONAL BATTERY CAPACITY
12-4 CARRIAGE BRAKE COMPONENTS . . . . . . . . 12-8 INDICATOR SCHEMATIC . . . . . . . . . . . . . . . 12-60
12-5 CHASSIS BRAKE COMPONENTS . . . . . . . . . 12-10 12-39 OPTIONAL BATTERY CAPACITY
12-6 CHASSIS BRAKE COMPONENTS . . . . . . . . . 12-12 INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 12-61
12-7 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 12-14 12-40 OPTIONAL FLASHING RED LIGHT . . . . . . . 12-62
12-8 BASE AND FRAME . . . . . . . . . . . . . . . . . . . . . 12-16 12-41 OPTIONAL FLASHING RED LIGHT
12-9 DECAL LOCATION . . . . . . . . . . . . . . . . . . . . . 12-18 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . 12-63
12-10 LOAD WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . 12-19 12-42 OPTIONAL SIDE GUIDE ROLLERS . . . . . . . 12-64
12-11 ELEVATION SYSTEM (SSCM 20-67). . . . . . . 12-20 12-43 OPTIONAL SAFETY HARNESS AND
12-12 ELEVATION SYSTEM (SSCM 20-130). . . . . . 12-22 LANYARD . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-65
12-13 LIFT CARRIAGE . . . . . . . . . . . . . . . . . . . . . . . 12-24 12-44 STANDARD SAFETY BELT AND LANYARD 12-66
12-14 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . 12-26 12-45 OPTIONAL SAFETY BELT . . . . . . . . . . . . . . 12-67
12-15 CARRIAGE OPERATED MANUAL 12-46 OPTIONAL SLIP ON PLATFORM . . . . . . . . . 12-68
LOWERING COMPONENTS . . . . . . . . . . . . . 12-28 12-47 OPTIONAL QUICK DISCONNECT CABLES 12-69

LIST OF TABLES

Table Page Table Page

2-1 OPERATOR CHECKS . . . . . . . . . . . . . . . . . . . . 2-2 3-3 LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . 3-3
3-1 MONTHLY AND QUARTERLY INSPECTION 4-1 TROUBLESHOOTING CHART . . . . . . . . . . . . . . 4-1
AND SERVICE CHART . . . . . . . . . . . . . . . . . . . . 3-1 4-2 CONTROLLER SPECIFICATION . . . . . . . . . . . . 4-4
3-2 RECOMMENDED LUBRICANTS . . . . . . . . . . . . 3-2

900980 iii
 OPERATOR INSTRUCTIONS

WARNING

Do not operate this truck unless you have been trained travel with load uphill. When truck is empty, travel with
and authorized to do so and have read all warnings lifting mechanism downhill.
and instructions in operator's manual and on this truck. Do not overload truck. Check capacity plate for load
Do not operate this truck until you have checked its weight and load center information.
condition. Give special attention to Tires, Horn, Lights,
Before lifting be sure load is centered, forks are com-
Battery, Controller, Lift System, (including forks or
pletely under load and load is as far back toward oper-
attachments, chains, cables and limit switches),
ator's platform as possible.
Brakes, Steering Mechanism, Guards and Safety
Devices. Do not handle unstable or loosely stacked loads. Use
special care when handling long, high or wide loads to
Operate truck only from designated operating position.
avoid losing the load, striking bystanders, or tipping
Never place any part of your body into the mast struc-
the truck.
ture, between the mast and the truck, or outside the
truck. Put on operator's safety harness when so Do not operate truck without an overhead guard.
equipped. Elevate forks or other lifting mechanism only to pick up
Observe applicable traffic regulations. Yield right of or stack a load. Watch out for obstructions, especially
way to pedestrians. Slow down and sound horn at overhead.
cross aisles and wherever vision is obstructed. Do not lift personnel except on a securely attached
Start, stop, travel, steer and brake smoothly. Slow specially designed Work Platform. Use extreme care
down for turns and on uneven or slippery surfaces that when lifting personnel. Make sure mast is vertical.
could cause truck to slide or overturn. Use special Place truck controls in neutral and apply brakes. Lift
care when traveling without load as the risk of overturn and lower smoothly. Remain in operating position or
may be greater. immediate vicinity as long as personnel are on the
Work Platform.
Travel with lifting mechanism as low as possible.
Always look in direction of travel. Keep a clear view, Do not allow anyone to stand or pass under load or lift-
and when load interferes with visibility, travel with load ing mechanism.
or lifting mechanism trailing (except when climbing Before getting off truck, neutralize travel control. Fully
ramps). lower lifting mechanism and set brake. When leaving
Use special care when operating on ramps. travel truck unattended, also shut off power.
slowly, and do not angle or turn. When truck is loaded

iv 900980
 PREPARATION FOR USE

Upon receipt, visually inspect vehicle and battery 3. Check battery, recharge if necessary and con-
charger. If any damage is found, report it to the carrier nect. If the vehicle was ordered without a battery,
and to your Big Joe dealer immediately. a freshly charged battery of adequate size and
proper weight must be installed. Refer to "Battery
Remove cardboard banded over carriage and over
Care" in SECTION 3 for battery checking instruc-
base of truck. Check vehicle and battery charger for
tions.
scratches and dents. Check to make sure that the lift
chains are secure. Inspect for oil leaks and loose wir- CAUTION: The batteries are extremely heavy (over
ing connections. Make certain that all accessories and 100 pounds each). Do not attempt
attachments that were ordered are supplied. removal or installation without assistance
Provisions have been made to prevent the lift carriage or proper equipment.
from being moved from a predetermined position dur-
4. Connect positive lead to pump motor (inside con-
ing transit. These include the following:
trol cabinet).
1. The positive lead of the lift pump has been dis-
5. The lift carriage is now ready for normal opera-
connected.
tion.
2. The lift carriage is banded down to the straddle
Refer to SECTION 2 for operating instructions and test
legs.
the following controls:
To place the lift carriage in operation, perform the fol-
Directional Switch
lowing steps:
Brake Pedal
1. Cut banding which holds the lift carriage to strad-
dles. Braking with Directional Switch
2. Remove 4 x 4 blocks and banding from carriage. Lift Control
If you do not obtain the proper results, or if improper
operation occurs, refer to troubleshooting in SECTION
4.

900980 v
 SECTION 1
DESCRIPTION

1-1. INTRODUCTION. 1-2. GENERAL DESCRIPTION.

This publication describes the SSCM series of coun- The self-propelled SSCM lifts and transports the oper-
terbalanced stock selector lift trucks manufactured by ator (on the platform portion of the lift carriage) and the
Big Joe Manufacturing Company, Des Plaines, Illinois, payload (on forks or optional payload platform). This
60018. Included are operating instructions, planned permits efficient selection and moving of materials in
maintenance instructions, lubrication procedures, cor- any area or at any level of the warehouse or store-
rective maintenance procedures and a complete parts room. The design permits one man to perform all oper-
list with parts location illustrations. ations of selecting the stock, driving the truck, and
replacing the stock at the designated place. The bat-
Users shall comply with all requirements indicated in
tery-powered vehicle is quiet and without exhaust
applicable OSHA Standards and current edition of
A.N.S.I. B56.1 Part II. By following these requirements fumes, allowing operation in closed areas without spe-
and the recommendations contained in this manual, cial provisions for ventilation.
you will receive many years of dependable service The SSCM 20 Series trucks are capable of lifting and
from your Big Joe Stock Selector. lowering a 2000-pound payload at a fixed speed.
The model number will be found on the name plate A steerable drive wheel makes the vehicle highly
(Figure 1-1) along with the serial number, lifting capac- maneuverable. Two separate braking methods may be
ity, and load center. employed by the operator to stop the SSCM.
The battery-powered truck is quiet and without
exhaust fumes.
The reversible DC motor propels the vehicle in forward
or reverse direction throughout the available speed
range. The SSCM can be driven with the carriage
MODEL NO. SERIAL NO.
raised or lowered; however the speed is restricted
COMPLIES WITH THE APPLICABLE

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

REQUIREMENTS OF ANSI B56.1
AND OSHA STANDARDS
when the lift carriage is raised above 24 inches.
ALT CAP LB/ KG LOAD CTR IN/ MM LIFT HGT IN/MM
U.S. PATENT NO. 4,444,284
AUSTRALIAN PATENT NO. 537,987
SSCM lift capacities generally are established at a 24-
TRUCK WT LESS BATTERY LB/ KG BATTERY MIN WT LB/KG
BIG JOE MANUFACTURING COMPANY inch load center. Additional lifting equipment such as
WISCONSIN DELLS, WISCONSIN 53965

removable payload platforms and special attachments

TRUCK WT WITH BATTERY LB/ KG BATTERY MAX WT LB/ KG TRUCK TYPE BATTERY TYPE CERTIFIED VOLTAGE

may alter the load center, and consequently lower the

OEM TYPE ATTACHMENT COMB SERVICE WT LESS BATTERY LB/
KG ATTACHMENT SERIAL NO.
rated lifting capacity of the vehicle.
MAX CAP LB/ KG LOAD CTR IN/ MM LIFT HGT IN/MM

1-2.1. Weight

CAUTION: Use of a battery (ies) weighing less than

the weight specified on the truck data
R6423
plate will affect vehicle stability.

Figure 1-1 Name Plate Weight distribution of a counterbalanced vehicle is crit-

ical; therefore the weight of the batteries is very impor-
tant. Standard trucks are equipped with two polymer
cased batteries. Option single industrial batteries can
also be used. Battery (ies) of less than minimum
weight (see data plate) will adversely affect stability,
particularly with the lift carriage raised. The battery
compartment is fabricated for the battery purchased
with the truck. The replacement battery (ies) must be
of proper size and weight for your SSCM. The battery
spacer must be placed between the battery and the
mast when a spacer is required.

900980 1-1
1-3. SAFETY FEATURES. 1. Hour Meter.
The SSCM is designed with many standard features. 2. Battery Discharge Indicator with or without Lift
Some of the convenience options also have safety Lockout.
applications. The following safety features are stan- 3. Operator safety belt, harness or tether.
dard:
4. Automatic lift limit with or without override.
1. Dead-man brake to prevent accidental runaway.
5. Automatic Travel Cutoff.
2. All operator controls automatically return to off
6. Industrial batteries with corresponding battery
when released.
chargers.
3. Automatic high speed limit switch to restrict speed
7. Battery compartment rollers for industrial batter-
when lift carriage is raised above 24 inches.
ies.
4. Key-operated power switch to prevent operation
8. Removable payload platform.
by unauthorized personnel.
9. Flashing red warning light.
5. Chain/post enclosure around operator compart-
ment. 10. Pallet clamping device.
6. Slip resistant surface on brake pedal and opera- 11. Aisle guide rollers.
tor's compartment floor. 12. Special operators compartment size.
7. Shatterproof plexiglass screen on the front of the 13. Charger Cord.
platform between operator and moving mast
14. Manual lowering from lift carriage
members.
8. Operator Safety Belt With Lanyard. If your Big Joe vehicle has optional equipment or fea-
tures not covered by this technical manual, check with
9. Overhead guard to protect operator from falling your Big Joe dealer for applicable supplements or
parts. addenda.
10. Emergency power disconnect system.
11. Horn. 1-5. SAFETY SYMBOLS.

12. Drive wheel position indicator. WARNING: This WARNING sign denotes a hazard. It
calls attention to a procedure, practice or
13. Manually actuated lowering valve for independent
the like, which if not correctly performed
lowering control of the operator's platform in the
or adhered to could result in personal
event of power loss or emergency disconnect.
injury.
14. Hangup feature to stop descending cylinder and
mast if lift carriage hangs up on an obstruction. CAUTION: This CAUTION sign denotes a hazard. It
calls attention to a procedure, practice or
15. Pressure relief valve to protect hydraulic system
the like, which if not correctly performed
from excessive pressures.
or adhered to could result in personal
16. Automatically controlled lowering speed should a injury or damage to the equipment.
hydraulic hose fail.
17. Automatically controlled speed acceleration IMPORTANT:This heading calls attention to a proce-
should the operator inadvertently advance the dure, which if not followed, may impede
speed control to maximum speed. the operation or normal flow of a servic-
ing or repair procedure.
1-4. OPTIONS AND ACCESSORIES.
Your vehicle may be equipped with any or all of the fol-
lowing options:

1-2 900980
 SECTION 2
OPERATION

2-1. GENERAL. 4. Do not handle unstable or loosely stacked loads.

This section gives detailed operating instructions for Use special care when handling long, high, or
the counterbalanced stock selector lift truck. The vari- wide loads to avoid tipping, loss of load, or striking
ous functional systems are first explained to provide a bystanders.
broad understanding of how the vehicle operates, fol- 5. Center and carry the load as far back toward the
lowed by step-by-step operating procedures. Routine lift carriage as possible. Do not pick up loads on
precautions are included for safe operation. the tips of the forks. The center-of-gravity of the
load must not exceed the load center listed on the
2-2. OPERATING PRECAUTIONS. name plate. See Figure 2-1 for load center limita-
tions.
WARNING: Improper operation of the stock selector
lift truck may result in operator injury, or 6. Pick up loads on both forks. Do not pick up loads
load and/or lift truck damage. Observe on only one fork.
the following precautions when operating 7. Always lower load when traveling to increase
the stock selector lift truck. vehicle stability.
8. When stacking pallets in racks, it is necessary to
1. Do not operate this truck unless you have been
move the load in the raised position. Move slowly
trained and authorized to do so, and have read
and use care when turning at a right angle.
and understand all warnings and instructions in
this manual and on the lift truck. 9. Check for obstructions when raising or lowering
2. Do not operate this truck until the periodic inspec- the lift carriage.
tion or service has been completed. See 10. Apply the mechanical brake gently except in
Table 3-1. cases of emergency.
3. Overloading will result in damage to the hydraulic 11. Observe applicable traffic regulations. Yield right
system and lift mechanism. Do not exceed the of way to pedestrians. Slow down and sound horn
rated lifting capacity. at cross aisles and wherever vision is obstructed.

SAFE UNSAFE

R3814

Figure 2-1 Load Center

900980 2-1
2-3. BEFORE OPERATION proper lubrication, proper fluid levels,
brake maintenance, motor maintenance
Table 2-1 covers important inspection points on SSCM
and other areas specified in the SEC-
lift truck which should be checked prior to operation.
TION 3.
Depending on use, some trucks may require additional
checks. WARNING: If the truck is found to be unsafe and in
Figure 2-2 shows a sample format for a Operator need of repair, or contributes to an
Checklist, which can be modified as necessary to fit unsafe condition, report it immediately to
your operation. the designated authority. Do not operate
it until it has been restored to a safe
WARNING: Periodic maintenance of this truck by a operating condition. Do not make any
QUALIFIED TECHNICIAN is required. unauthorized repairs or adjustments. All
service must be performed by a qualified
CAUTION: A QUALIFIED SERVICE TECHNICIAN
maintenance technician.
should check the truck monthly for

Table 2-1 Operator Checks

ITEM PROCEDURE ITEM PROCEDURE
Transmission Check for signs of fluid leakage. Wheels Check drive wheel for cracks or
and hydraulic damage. Move truck to check
systems. load wheels for freedom of rota-
tion.
Forks Check for cracks and damage;
and, that they are structurally Hydraulic con- Check operation of lift and lower
secure. trols to their maximum positions.

Chains, cables Check that they are in place, Brakes Check that brakes release when
and hoses secured correctly, functioning the brake pedal is depressed.
properly and free of binding or
damage. Deadman/Park- Check that brake pedal raises to
ing brake upright position when released
Guards Check that safety guards are in and brake applies.
place, properly secured and not
damaged. Battery discon- Check that battery can be
nect disconnected and reconnected.
Safety signs Check that warning labels, Check for connector damage.
nameplate, etc., are in good
condition and legible. Battery charge Check that battery capacity
meter (if equipped) is on “F”.
Horn Check that horn sounds when
operated. High speed limit Allow for enough space to oper-
switch ate truck in high speed. Elevate
Steering Check for binding or looseness in forks approximately two feet,
steering wheel when steering. then test drive truck to check if
high speed is cut out.
Travel controls Check that speed control lever
operates in all speed ranges in
forward and reverse.

2-2 900980
 R5659

Figure 2-2 Sample of Operator Check List

900980 2-3
2-4. INSTRUMENTS AND CONTROLS (Figure 2-3) 2-5. OPERATION
Key Switch (1): Used to prevent unauthorized per- 2-5.1. Driving and Stopping Procedures
sonnel from operating the lift truck. (Figure 2-3)
Brake Pedal (2): Used to release the mechanical Proceed as follows to start and stop the stock selector
brake when depressed and engage the brake when lift truck:
released.
1. Step on the platform facing the control console
Steering Wheel (3): Used to control the direction of and turn the key switch (1) on.
travel.
2. Step on the brake pedal (2) to release the brake
Directional Control (4): Used to control the direction and to activate the electrical controls.
and speed of the truck. 3. Note position of the drive wheel position indicator
Lowering Pushbutton (5): Used to lower the opera- (8).
tor's platform and forks from the raised position. 4. Place one hand on the steering wheel (3) and be
prepared to steer the vehicle in the desired direc-
Emergency Power Disconnect Switch (6): Used to
tion.
disengage the emergency power disconnect located
inside the base and frame compartment, disconnect- 5. To move forward, slowly twist the directional con-
ing all power to the truck in case of an emergency. trol (4) forward. The vehicle will creep forward.
Twisting the control further causes the speed to
Horn Pushbutton (7): Used to sound the horn. increase.
Steer-Wheel Position Indicator (8): Used to indicate 6. To stop, lift foot slowly from the brake pedal (2) as
the position of forward travel of the drive wheel. you release the directional control (4).
Optional Hourmeter (9): Used to record the accumu- NOTE: Additional procedures for stopping are
lated hours that electrical energy is being drawn from described in paragraph 2-5.2.
the battery to run the pump and drive motors.
7. To stop rapidly when an emergency exists, quickly
Optional Flasher Switch (10): Used to control the lift foot from brake pedal.
optional flashing red light.
WARNING: Except in an emergency, do not stop
Lift Pushbutton (11): Used to raise the operator's suddenly. Lift foot slowly from the brake
platform and forks from the lower position. pedal.
Optional Pallet Clamp (12): Used to secure a pallet 8. To move in reverse, slowly twist the directional
on the forks. control (4) to the rear. Twisting the control further
Optional Lift Limit Override (13): Used to override causes the speed to increase.
the lift limit switch allowing additional lifting of the oper-
NOTE: Vehicle direction may be reversed while mov-
ator's platform and forks.
ing. The transistor speed control unit will
Battery Capacity Indicator (14): Used to monitor the cycle the motor to a stop and a reverse in a
battery discharge rate to indicate the remaining battery timed sequence without danger to the equip-
capacity. ment. Exercise caution when doing so, espe-
Optional Manual Lowering Lever (15): Used to man- cially when traveling at maximum speed.
ually lower the operator's platform and forks in case of 2-5.2. Braking (Figure 2-3)
a power loss.
Following are the various methods for stopping the
Charger (16): Used to recharge the battery.
stock selector lift truck:
EPD Energize Switch (17): Trucks serial number
Release the directional control (4) and lift your foot
334774 to 356020, used to energize the truck after an
from the brake pedal (2).
emergency power disconnect.
Using the directional control (4), reverse direction.
EPD Energize Switch (18): Trucks serial number
356021 to 374092, used to energize the truck after an Release the directional control (4) and allow the vehi-
emergency power disconnect. cle to coast to a stop.

2-4 900980
 R3154

Figure 2-3 Operator’s Controls

2-5.3. Operating Lift (Figure 2-3) NOTE: The lift carriage will rise as long as the lift
pushbutton is depressed, or until the lift car-
Proceed as follows to raise and lower the lift carriage:
riage reaches maximum height.
1. Step onto the platform and stand near the control
station. 4. Release the lift pushbutton when the lift carriage
reaches the desired height.
NOTE: It is not necessary to release the brake. For
5. To lower the lift carriage, press the lower pushbut-
maximum safety, leave the brake on.
ton switch (5).
2. Turn on the key switch (1). 6. When the lift carriage reaches the desired level,
release the lower pushbutton switch (5).
WARNING: Check the space above your head and
above the entire carriage to be sure that 2-5.4. Emergency Lowering
the platform mast or load will not hit any
obstructions while being raised. In case of power loss a manually operated lowering
valve (43, Figure 12-14) is located adjacent to the
3. To raise the lift carriage, depress the lift pushbut- pump motor on standard models. The valve is accessi-
ton switch (11). ble by opening the upper access door. Turn the valve
handle slowly until the carriage starts to descend.
When the carriage is completely lowered close valve.

900980 2-5
An optional carriage operated manual lowering valve 2-5.8. Load Handling.
is installed on some trucks. This lowering valve allows
Proceed as follows to pick up or move a load on stock
an operator on a raised carriage to lower the carriage
selector lift trucks equipped with forks:
at a controlled rate when power is not available such
as when the Emergency Power Disconnect has been 1. Before moving vehicle, lower the lift carriage.
activated. When this option is installed a red lever is
NOTE: Lowering the lift carriage lowers the vehicle
also added to the lowering valve (28, Figure 12-15) on
center of gravity, which in turn increases the
the chassis. This lever is accessible by opening the
stability when traveling.
upper access door. Pressing the lever will cause the
carriage to descend. 2. Move the lift vehicle to the pick-up area.
2-5.5. Emergency Power Disconnect (Figure 2-3) 3. Raise forks to the desired height for entry into the
pallet or skid.
In an emergency, all power can be turned off at once
by depressing the EMERGENCY POWER DISCON- 4. Move into position, so that the forks are within the
NECT (EPD) PUSHBUTTON SWITCH (6). Once this pallet or skid and the load is centered over the
circuit is actuated, none of the electrical controls will forks.
operate until the circuit is reset, but the lift carriage can 5. Move the vehicle to place load against edge of
be lowered using the manual lowering controls. (See operator deck; then raise forks to lift the pallet.
paragraph 2-5.4.)
CAUTION: Avoid spilling the load. Move slowly and
CAUTION: For trucks Serial Number 334774 to use extra care when turning.
356020, before disconnecting the bat-
tery, make sure you can open the electri- 6. Slowly move the vehicle to free the load from its
cal compartment door to reset the EPD rack; then when load is clear of its rack, lower the
circuit. load leaving enough floor clearance to maneuver.
7. Drive carefully to area where the load is to be
To make the vehicle operable, the emergency power placed.
disconnect must be reset. For trucks Serial Number
334774 to 356020, the emergency power disconnect 8. Move vehicle to align load with its new position.
reset plunger is located on a bracket behind the upper 9. Raise loaded forks to the height desired and
access door. For trucks Serial Number 356021 to slowly drive into position.
374092, the emergency power reset is reset by press-
ing the PUSH TO ENERGIZE (EPD Reset) button CAUTION: The load must rest squarely on its rack
located on the right side of the truck. when it is lowered into position.

10. When the load is in position, lower the forks until

2-5.6. Parking
the pallet rests on its rack and the forks are free.
1. When finished moving loads, drive vehicle to its
11. Move backwards slowly, making sure that the
maintenance or storage area.
forks do not catch on the pallet and lower the
2. To park, lift your foot from the brake pedal. This forks when they are clear.
deactivates the electrical circuits and engages the
mechanical brake. 2-5.9. Pallet Clamp (Figure 2-3)
3. Turn off the key switch. The pallet clamp is operated by the pallet clamp
4. Charge battery as required, see SECTION 3. release lever (12). Raise the release lever to close the
clamp on the center strings of the pallet being moved.
2-5.7. Battery Charging The extension spring accommodates the clamp to
varying board widths.
Refer to Document 245 for battery safety and mainte-
nance. Lower the release lever to release the clamp; the
spring loading of the clamp then returns the clamp
NOTE: Battery charging instructions are contained in arms to their idle position.
SECTION 3.
2-5.10.Moving a Disabled Truck
Do not attempt to move a disabled truck. Notify your
supervisor or proper authority.

2-6 900980
 SECTION 3
PLANNED MAINTENANCE

3-1. GENERAL. vice should be increase accordingly. These proce-

Planned maintenance consists of periodic visual and dures must be performed by a qualified service
operational checks, parts inspection, lubrication, and technician or your Big Joe service representative.
scheduled maintenance designed to prevent or dis-
cover malfunctions and defective parts. The operator 3-3. BATTERY CARE.
performs the checks in SECTION 2, and refers any 3-3.1. General.
required servicing to a qualified maintenance techni-
cian who performs the scheduled maintenance and The life of the battery can be extended by giving it
any required servicing. proper care. Perform a daily check of the battery
whether or not the equipment is in daily use. DO NOT
3-2. PERIODIC CHECKS. overcharge the battery or battery life will be shortened.
DO NOT allow battery to become completely dis-
Table 3-1 is an inspection and service chart based on charged (specific gravity 1.150 or less). This will also
normal usage of equipment eight hours per day five greatly shorten battery life.
days per week. If the lift truck is used in excess of forty
hours per week, the frequency of inspection and ser-
Table 3-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check drive motor for proper operation
Monthly Check pump motor for proper operation
Monthly Check brake for proper operation
Monthly Check transmission for oil leaks
Monthly Check hydraulic system for leaks
Monthly Check hydraulic oil level
Monthly Check load wheels for wear
Monthly Check drive wheel for wear
Monthly Inspect wiring for loose connections and damaged insulation
Monthly Inspect contactor tips for excessive pitting and wear
Monthly Check lift chain tension, lubrication & operation (See paragraph 3-5.)
Monthly Lubricate unit (See Table 3-3)
Quarterly Check lift cylinder for leakage
Semi-annually Replace hydraulic filter assembly
Semi-annually Inspect for chain wear (See paragraph 8-4.)

900980 3-1
 CAUTION: Use distilled water. Impurities in tap
water will damage battery plates.

4. Charge battery as necessary.

NOTE: A fully charged battery has a specific gravity

of 1.260 to 1.275.

5. After charging, check water level in each cell

again. Water level must cover plates but not be
higher than the base of the battery cell filler neck.

3-4. LUBRICATION.
Refer to Table 3-2 for the recommended types of
grease and oil. Table 3-3 in conjunction with Figure 3-1
identifies the items requiring lubrication.
Table 3-2 Recommended Lubricants
(See Table 3-3 for Application)
3-3.2. Battery Servicing.
No. 1 Transmission oil—EP SAE 80W-90 (in
Refer to Document 245 for battery safety and mainte- temperatures below 32°F use 10W-30)
nance.
Perform the following procedures at end of each day: Transmission oil capacity is 3 pints.

1. Obtain a battery hydrometer. No. 2 Grease—Lithium base, general purpose.

NOTE: These can be obtained from a local hardware
store or automotive shop. No. 3 Hydraulic oil-Heavy duty with a viscosity of
150 SUS (in temperatures below 32°F
2. Open the battery cover and remove the vent caps. use 100 SUS) foam suppressing agent
3. Use the hydrometer to check specific gravity of and rust and oxidation inhibitors.
each cell.
Big Joe Part No.900855 (1 gallon)
NOTE: Battery specific gravity readings should agree 900893 (1 quart)
within ±0.025 from cell to cell. If variation is
greater, the battery may have to be repaired No. 4 SAE 30 or 40 Engine lubricating oil
or replaced.

CAUTION: Be sure that no cell plates are exposed

(not covered by fluid) before charging. 3-5. LIFT CHAIN MAINTENANCE.
Add distilled water sufficient to just cover
top of cell places. Fully raise and lower lift carriage while observing
chains as they move over all chain sheaves. Ensure
chain is aligned and tracking properly and all links are
pivoting freely. With carriage fully lowered, spray or
brush on a film of SAE 30 or 40 engine oil.

3-2 900980
 6

R5662

Figure 3-1 Lubrication Diagram

Table 3-3 Lubrication Chart
FIG 3-3 LOCATION METHOD OF TYPE APPLICATION
INDEX APPLICATION (Table OF
NO. 3-3) LUBRICANT
1 Transmission Can No. 1 Fill to plug level.
2 Mast and inner mast Brush No. 2 Clean off old grease and apply a
thin coat the full length of mast
where rollers touch.
3 Hydraulic system Can No. 3 Fill, so oil shows full on dipstick
with lift carriage fully lowered.
4 Chain sheaves Gun No. 2 Pressure lubricate.
5 Lift carriage rollers Gun No. 2 Pressure lubricate.
6 Lift chains Brush or Spray No. 4 See Paragraph 3-5.

900980 3-3
 NOTES

3-4 900980
 SECTION 4
TROUBLESHOOTING

4-1. GENERAL wiring diagram (Figure 4-10 or Figure 4-11 as applica-

Table 4-1 serves as a guide to determine possible ble) as a supplement to the troubleshooting chart or
causes of trouble. The table is divided into five main when tracing an electrical circuit.
categories: Truck Dead: Trouble With Travel: Trouble
With Braking: Trouble With Lifting Or Lowering, and 4-2. Circuit Operation
Miscellaneous Malfunctions. In order to troubleshoot While operation of the transistorized control system is
the transistor speed control, Paragraph 4-2. contains automatic, it is helpful to understand the operating
theory of operation and Paragraph 4-3. contains trou- principles and features of the transistor controller
bleshooting procedures for the transistor speed con- when troubleshooting trucks equipped with this con-
trol. Paragraph 4-4. contains adjustments of the troller. The controller is mounted on the controller
transistor speed control. Refer to electrical schematic panel, installed within the main housing of the lift truck.
(Figure 4-8 or Figure 4-9 as applicable) and electrical Figure 4-1 identify the contacts of a typical controller.
Table 4-1 Troubleshooting Chart
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TRUCK DEAD
Truck will not run in forward or in a. 300 Amp fuse blown or 15 amp Check fuse and replace if defective.
reverse, and platform will not fuse blown.
rise. Hourmeter does not run. b. Battery dead or disconnected. Check battery quick-disconnect
plug.
Check battery (See SECTION 3).
c. Defective key switch. Check and replace if required.
d. Defective wiring. Check for open circuit. Repair as
required.
e. Emergency power disconnect cir- Refer to paragraph 4-5., then check
cuit off. and reset as required.
TROUBLE WITH TRAVEL
Platform operates, but drive a. Check all wiring. A loose connec- Tighten all loose connections before
motor will not run or lacks tion may be the cause of malfunc- further troubleshooting.
power. tion.
b. Open line. No positive voltage Check brake switch for open condi-
applied to directional switch. tion. Repair or replace.
c. Defective transistor speed control. Refer to paragraph 4-3.
TROUBLE WITH BRAKING
Mechanical brake does not stop a. Brake linkage in need of adjust- Adjust mechanical brake (See SEC-
truck properly. ment. TION 6).
b. Brake pads worn. Replace pads and readjust mechan-
ical brake.
Improper braking using direc- Defective transistor speed control Refer to paragraph 4-3.
tional switch. unit.

900980 4-1
 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH LIFTING OR LOWERING
Platform does not lift to top. a. Oil level too low. Check hydraulic oil level. Fill
hydraulic reservoir so that oil is
shown full on dipstick with the plat-
form fully lowered, before further
troubleshooting.
b. Load heavier than capacity. Refer to nameplate for maximum
load capacity.
c. Defective pump or motor. Replace.
Vehicle runs in forward and in a. Defective electrical system. If pump does not run when lift push-
reverse, but platform does not button is pressed, tighten electri-
raise. cal connections. Check for
positive DC voltage at pump motor
to locate defect. Repair or replace
defective part.
b. Defect in hydraulic system. Check for pinched hoses. Check
pump for proper operation.
Replace if necessary.
Vehicle runs and platform rises, a. Control valve defective or defect in Check control valve for proper
but will not go down. hydraulic system. action. Check for obstruction in the
hydraulic line. Repair as required.
b. Defective hangup valve. Replace.
Platform creeps downward Leak in hydraulic system. Look for loose fittings in the hydrau-
under load when in raised posi- lic line. Check the check valve and
tion. Everything else is normal. pump for leakage back into the
reservoir. Also check for overload-
ing or defective relief valve in
pump. Repair or replace as
required.
Squealing sounds from pump a. Oil level too low. Check hydraulic oil level. Fill
when platform is raised. hydraulic reservoir so that oil is
shown full on dipstick with the plat-
form fully lowered, before further
troubleshooting.
b. Dry channels in mast. Apply grease.
c. Defective bearing. Replace bearing.
d. Pinched suction or plugged filter. Check lines and replace filter as
applicable.
Miscellaneous
Oil sprays or flows from the top Defective packing in lift cylinder. Overhaul the lift cylinder and install
of the lift cylinder. new packing and seal.
Oil foaming in breather of Leak in the suction line between the Tighten fittings. Inspect line and
hydraulic reservoir. pump and the reservoir. replace if necessary.
Oil splashes out of breather Oil level too high. Drain, then refill reservoir when lift
when lowering platform. carriage is in the lowest position.

4-2 900980
4-2.1. Smooth Stepless Operation. one second to reach full output. This feature contrib-
utes to a smooth, gentle start. (See adjustment
The Big Joe custom transistor controller allows supe-
instructions to adjust acceleration ramp setting.)
rior operator control of the vehicle’s drive motor speed.
The amount of current delivered to the motor is set by 4-2.4. Current Limiting.
varying the “on” time (duty cycle) of the controller’s
transistors.This technique, called “pulse width modula- The transistor controllers limit the motor current to a
tion” (PWM), permits silent, stepless operation. preset maximum. This feature protects the controller
from damage that might result if the current were lim-
4-2.2. Current Multiplication. ited only by the motor demand. The current limit fea-
ture also protects the rest of the system. By eliminating
During acceleration and during reduced speed opera-
high current surges during vehicle acceleration, the
tion, the controller allows more current to flow into the
stresses on the motor and batteries are reduced and
motor than flows out of the battery. The controller acts
their efficiency and service life are improved. Similarly,
like a DC transformer, taking in low current and high
there is less wear and tear on the vehicle drive train.
voltage (the full battery voltage) and putting out high
current and low voltage. The battery only has to supply 4-2.5. Plugging.
a fraction of the current that would be required by a
conventional controller (in which the battery current A form of electrical braking called plugging can be
and motor current are always equal). The current mul- used to slow the vehicle. When the motor is reversed
tiplication feature gives vehicles using these control- with the accelerator advanced (i.e., when the vehicle is
lers dramatically greater driving range per battery moving), the armature acts as a generator. Current
charge. from the armature flows through a plug diode in the
controller. The controller regulates the current in the
4-2.3. Acceleration Limiting. motor field winding to give an appropriate level of plug-
ging torque. The vehicle slows smoothly to a stop,
A built-in acceleration limiting circuit maintains a maxi-
then automatically accelerates in the other direction. A
mum rate of power increase to the motor. If full throttle
tone may be heard during plugging. The maximum
is applied at start-up, the acceleration ramp setting
plugging current is factory set and is field adjustable
determines how quickly the output of the controller
(see adjustment instructions).
increases. The standard setting is such that with full
throttle applied, the controller requires approximately

R4086

Figure 4-1 Full Feature Electronic Motor Controller

900980 4-3
4-2.6. Undervoltage Protection Once the controller warms above -13°F (-25°C) full
current limit and performance return automatically.
The control circuitry requires a minimum battery volt-
age to function properly. The controller is therefore 4-2.9. Accelerator Fault Protection (Runaway Pro-
designed so its output is gradually reduced if the bat- tection).
tery voltage fails below a certain level; the cutoff volt-
age for this model is listed in the specifications (see To prevent uncontrolled operation, the controllers shut
Table 4-2). Reducing the output to the motor allows off the motor output in the event of a short circuit fault
the battery voltage to recover, and an equilibrium is in the accelerator or its wiring. The throttle configura-
established in which the battery supplies as much cur- tion is a 2-wire potentiometer ranging from 5000 ohms
rent as it can without failing below the cutoff voltage. for full off to 0 ohms for full on. The controller returns to
normal operation when the fault (e.g., accelerator wir-
Table 4-2 Controller Specification ing, broken connectors, potentiometers that fail) has
Big Joe Model 005467-02 been corrected.
Input Voltage 24-36
4-2.10.Controller Fault Protection.
Current Limit 400 Amps*
Rating: Faults can be caused internally (e.g., shorted transis-
tors) or externally (e.g., wrench or hardware dropped
2 Minute 300 Amps
across controller terminals). While disabled, the con-
5 Minute 210 Amps troller's direction contactor output and internal logic
1 Hour 135 Amps are both off.
Voltage Drop @ 100 Amps 0.25 V
Faults are detected by monitoring the controller's M-
Under-voltage Cutback 13 V output. If M-remains low for more than 20 ms, a fault is
Max F/R+1A Current 2 Amps detected. Fault protection is disabled for throttle
Operating Frequency 15 kHz demand greater than 80%.
Standby Current <20 mA To recover from a fault, the F/R switch must be turned
Standard Throttle Input 0-5000 ohms. off and back on again. If the fault has been corrected,
±10% the controller will turn back on.
* 30 Second rating.
4-2.11. Weather Resistance.
4-2.7. Overvoltage Protection. All controllers are housed in rugged epoxy-sealed,
Similarly, the controller has a means of preventing anodized aluminum extrusions that provide excellent
operation when battery voltage is too high for proper environmental protection.
functioning. Excess voltage can occur from an unregu-
lated battery charger or from improper or faulty wiring. 4-2.12.Arcless F/R Switching.
Each time the F/R switch passes through neutral, the
4-2.8. Thermal Protection. controller's output is rapidly turned off (even if the
Because they are well designed thermally, the control- throttle is held on) so that all motor current has
lers barely get warm in normal operation. If the internal stopped by the time the direction contactor drops out.
temperature of the controller exceeds 165°F, the cur- Controller output always starts at zero and increases
rent limit drops off steadily until it is reduced to zero at smoothly at the set acceleration rate each time a new
200°F. This allows the vehicle to be operated at a direction is selected.
reduced performance level in order to permit maneu-
vering out of the way and stopping in a good place. 4-2.13.High Pedal Disable (HPD).
After the controller cools down, full current and perfor- When the controller Key Switch Input (KSI) is turned
mance return automatically. The controller shifts fre- on, it will sense a “high” (advanced accelerator) and
quency during overtemperature from its normal 15 kHz will inhibit the output until the accelerator is released
to 1 kHz, providing an audible tone alerting the opera- and reapplied. By preventing the unit KSI from being
tor to the overtemperature condition. turned on with the throttle depressed, this safety fea-
The controller is also protected from undertempera- ture (also called Neutral Start) requires the truck to
ture. Should its internal temperature fall below -13°F (- start smoothly from zero throttle when the battery is
25°C) from being parked overnight in an icehouse, for plugged in. It also protects against sudden starts
example, the current limit will be 1/3 the maximum. caused when problems in the throttle linkage

4-4 900980
(e.g., bent parts, broken return spring) give a partial or can build up in and around the batteries.
full throttle signal to the controller even with the accel- Always follow the battery manufacturer's rec-
erator released when the battery is plugged in. ommendations when working around batter-
ies. Wear safety glasses.
4-3. Controller Troubleshooting
4-3.3. Check for Power to the Controller.
4-3.1. Tools Required
1. Leave the keyswitch off for these tests (if truck is
Metric Wrenches for Contactors so equipped).
Standard Wrenches 2. Verify that battery (-) connects to the B-terminal of
1/8 inch Allen Wrench the controller, Figure 4-1. Connect voltmeter (-)
Insulated Screwdrivers lead to this point.
Analog Volt-ohmmeter
Clamp on DC Ammeter or Shunt Ammeter Setup 3. Connect voltmeter (+) to the battery side of the
power fuse. Check for full battery voltage. If it is
4-3.2. Procedure not there, the trouble is in the battery pack or the
cables to it.
The following procedures are to fix vehicles that don't
operate properly. Refer to the basic wiring schematic 4. Connect the voltmeter (+) lead to the controller B+
(Figure 4-8 or Figure 4-9) when conducting these terminal. You should read full battery voltage. If
tests. Make sure the controller is hooked up as shown this voltage is zero or close to zero, the trouble is
in Figure 4-8 or Figure 4-9. Refer to the wiring diagram either a bad controller, a bad power fuse, or an
and schematic for your vehicle. These tests require a incorrectly connected cable. Trace the cable to
general purpose volt-ohmmeter; you can use either a make sure it is hooked up right. If these check
conventional “V-O-M” or an inexpensive digital voltme- out, the controller is malfunctioning.
ter.
4-3.4. Check for Contactor Operation and Key-
In general, when a problem has been isolated to the switch Input (KSI).
controller, remove and replace it. If the source of the
1. Turn the key on and depress brake pedal to
problem has not been determined or is suspected to
bypass deadman switch and release brake. Move
be within the truck (not the controller), proceed as
the accelerator in forward or reverse, until the
directed.
microswitch operates.
NOTE: Working on electric vehicles poses some 2. This should cause the forward or reverse contac-
dangers. You must protect yourself against tor to operate with an audible click. Connect the
runaways, high current arcs, and outgassing voltmeter across the contactor coil terminal. You
from lead acid batteries: should see full battery voltage.

Runaways — Some fault conditions could 3. The controller KSI terminal (top push on) (see Fig-
cause the vehicle to run out of control. We ure 4-1) should also be getting full battery voltage.
suggest that you jack up the vehicle and get Verify this with the voltmeter. Connect the voltme-
the drive wheels off the ground before ter (-) to the controller B-terminal, and the voltme-
attempting these procedures or any other ter (+) to the controller's KSI terminal.
work on the motor control circuitry. 4. If the contactor and KSI terminal are not getting
voltage, that's the problem. Use the voltmeter to
High current arcs — Electric vehicle batter- find out where it is not getting through. Connect
ies can supply very high power for short the voltmeter (-) to the controller's B-terminal and
times. If they are accidentally short circuited, check the following points with the voltmeter (+)
arcs can occur. Always open the battery cir- lead to trace the flow:
cuit before doing work on the motor control a. First, check both sides of the control wiring
circuit. Wear safety glasses and use properly fuse.
insulated wrenches to prevent accidental
shorts. b. Check both sides of the keyswitch (if truck is
so equipped).
Lead acid batteries — Charging or discharg- c. Check both sides of the accelerator
ing batteries generates hydrogen gas, which microswitch.

900980 4-5
 d. Finally, check the contactor coil and controller troller's B- terminal). The keyswitch must be on,
KSI. the brake pedal depressed (to bypass deadman
switch) and a directional switch engaged for this
5. If the contactor coil and KSI are getting voltage,
test.
make sure that the contactor is really working, by
connecting the voltmeter across its big terminals.
Lower Terminal
There should be no measurable voltage drop. If
Accelerator at Start: 2.7 volts
you see any at all, the contactor is bad.
Accelerator at Maximum: 7.0 volts
4-3.5. Check Potentiometer Circuitry. Compare your readings with these; if they are dif-
ferent by more than a few tenths of a volt, contam-
The following procedure applies to the basic accelera- ination is probably the trouble.
tor input configuration for these controllers, which is a
nominal 5000 ohm potentiometer connected as a two- 6. Carefully clean off the terminal area of the control-
wire rheostat (0 ohms = full on, 5000 ohms = full off). ler with a cotton swab or clean rag moistened with
Some controllers are sold with other input characteris- water, and dry thoroughly. Now test the controller
tics. If your installation used one of these optional to see if proper operation is restored. If so, you
inputs, find out what its range is and use a procedure should take steps to prevent this from happening
comparable to the following to make sure your accel- again. You must keep dirt and water from reach-
erator is working correctly. ing the terminal area of the controller.

1. With the forks lowered, the keyswitch off, and the 4-3.6. Check for Controller Output.
battery disconnected, pull off the connectors
1. Disconnect the wire from the direction contactors
going to the accelerator inputs of the controller.
to the F/R contactor output of the controller.
(See Figure 4-1). Connect an ohmmeter to the
two wires and measure the resistance as you 2. Connect the voltmeter (+) lead to the controller's
move the accelerator. The resistance at the limits B+ terminal. Connect the voltmeter (-) lead to the
should be within these ranges: controller's M- terminal.
3. Connect the battery, turn on the keyswitch,
Accelerator at Start: 4300 ohms to 4800 ohms depress the brake pedal (to bypass deadman
Accelerator at Maximum: 0 ohms to 50 ohms switch), move the accelerator in forward, and
2. If these resistance's are wrong, it is because the watch the voltmeter as you advance the accelera-
potentiometer itself is faulty or out of adjustment, tor. The voltmeter should read zero with the accel-
the wires to the pot are broken or disconnected, erator released, and should read full battery
the linkage is not moving the pot shaft through its voltage with the accelerator at maximum. If it does
proper travel or a switch, resistor, or the relay is not, the controller is bad and must be replaced. If
defective or incorrectly wired. (See Figure 4-10 or the voltmeters readings are appropriate, release
Figure 4-11 as applicable.) the accelerator, turn off the keyswitch, disconnect
the battery, and reconnect the wire to the direction
3. While you have the accelerator wires off the con-
contactors.
troller, use an ohmmeter to check for shorts
between these wires and the vehicle frame. You 4. The next step is to measure the current in the
should see a resistance of at least 10,000 ohms. controller's M- lead. If you have a means of mea-
If it is lower than that, inspect the wiring for dam- suring this high dc current, such as a shunt/meter
aged insulation or contact with the frame. If nec- setup or a clamp-on dc ammeter, use it.
essary, replace the potentiometer. 5. Connect the battery, turn the keyswitch on,
4. Push the wires back on the controller terminals. depress brake pedal (to bypass deadman switch),
move the accelerator in either forward or reverse,
5. Inspect the terminal area of the controller closely.
and watch the ammeter while advancing the
Occasionally a build-up of dirt or acid residue of a
accelerator.
conductive nature may cause electrical leakage
between the accelerator input terminals and the 6. If you see no current flowing in the M- lead, the
B- or M- terminals, leading to faulty accelerator problem is an open circuit in the motor or the wir-
operation. To check for this problem, measure the ing between the motor and the controller. Check
voltage at the lower pot terminal or at controller the F/R switch. Check contactors for reversing,
(by connecting the voltmeter (-) lead to the con- check to see that they are operating and that their

4-6 900980
 contacts are closing. If these are okay, check the rately if it is suspected of having a shorted wind-
motor armature and field for opens. ing.
7. If you do see a high current flowing in the M- lead, 10. Verify all illustrated connections and componentry
but the motor does not turn, the problem is either (Figure 4-10 or Figure 4-11) within the truck. If all
a short in the motor circuit, a miswired motor, or a checks out and the source of the problem still has
short in the controller's internal plug diode. Test not been found, replace the controller.
the plug diode as follows:
a. Remove power by opening the battery circuit. 4-4. Adjustment of Controller Potentiometers
Take the cable off the controller's A2 terminal. The controller has adjustable plug current, current
limit, and acceleration rate settings. The locations of
b. Use an ohmmeter to check the resistance
the adjustment pots are shown in Figure 4-2.
between the controller's A2 and B+ terminals.
You are testing for the presence of a diode NOTE: Stop the truck and release the handle during
inside the controller, so swap the two leads of adjustment.
the ohmmeter and look for a low resistance
one way and a much higher one the other 1. Remove the socket head screw (1/8” Allen) for
way. If your meter has a diode test function, the adjustment you want to make.
use it. 2. Adjust the internal potentiometer with a small
c. If you find the diode to be shorted, the con- insulated screwdriver, in order to provide the
troller is bad and needs to be replaced. desired performance for the identified characteris-
tics.
8. Put the A2 cable back on the controller.
3. Replace socket head screw and nylon seal
9. If the plug diode is OK, there is a short in the
washer. Tighten to 8 inch-pounds maximum to
motor circuit. An ordinary ohmmeter will not work
prevent stripping.
to find the short, because the resistances of the
motor windings are so low. Test the motor sepa-

R4088

Figure 4-2 Location of Adjustment Pots

900980 4-7
4-5. EPD TROUBLESHOOTING Amp fuse, through the 15 Amp fuse, through EPD
(Trucks Serial Number 356021 to 374092) relay contacts 9 and 6, through the closed EPD switch,
to terminal A on the EPD relay. This keeps the EPD
4-5.1. Emergency Power Disconnect Circuit Oper- contactor energized maintaining battery negative to
ation the truck circuits.
The Emergency Power Disconnect (EPD) is designed When the EPD switch is pressed, the circuit to EPD
to remove operating power from the truck quickly in an relay terminal A is opened and the EPD relay is deen-
emergency. The circuit is shown in Figure 4-3. To ergized. EPD Relay contacts 9 and 6 open and
apply power to the lift truck the PUSH TO ENERGIZE remove battery voltage from the EPD contactor, deen-
(EPD Reset) switch must be pressed momentarily. To ergizing the contactor. With EPD relay contacts 9 and
remove power quickly either the battery must be dis- 6 open voltage is also removed from the EPD switch
connected or the EPD switch must be pressed circuit. Thus when the EPD switch is released the
momentarily. Circuit operation is as follows: EPD relay and contactor remain deenergized.
The negative side of the battery is connected to the Pressing the EPD switch is the normal way of deener-
following three points. gizing the truck and setting the EPD to its initial condi-
1. One side of the EPD contactor coil which is deen- tion with the EPD contactor open. Disconnecting the
ergized at this time. battery will also causes the EPD circuit to be deener-
gized and returned to its initial state.
2. One power contact on the de energized EPD con-
tactor. Remember that the EPD circuit is energized initially by
3. One side of the EPD relay coil which is deener- pressing the PUSH TO ENERGIZE switch momen-
gized at this time. tarily and is held in the activated state by the holding
circuit through the EPD switch.
The positive side of the battery is connected through
the 300 amp fuse then through the 15 Amp fuse to the 4-5.2. Troubleshooting Procedure
common contact on the PUSH TO ENERGIZE switch. Before trying to troubleshoot the EPD circuitry, read
Initially both the EPD relay and the EPD contactor are the Emergency Power Disconnect Circuit Operation,
deenergized and the lift truck is inoperative. paragraph 4-5.1. Understanding the general overall
When the PUSH TO ENERGIZE switch is pressed function and operation will simplify isolating faults.
momentarily the positive battery voltage is applied The following troubleshooting information is based on
through the switch to terminal A on the EPD relay. using a multimeter set to measure DC voltage on a
Since terminal B is connected to the negative side of scale appropriate for measuring 24 VDC.
the battery, the relay is energized and contacts 6 and 9 1. If the emergency Power Disconnect will not
close. This completes a circuit from the 15 Amp fuse engage, use the logic flow diagram, Figure 4-4, to
through closed contacts 9 and 6 of the EPD relay to isolate the faulty component.
the negative side of the battery and the contactor
energizes connecting battery voltage to the B-terminal 2. If the Emergency Power disconnect does not dis-
of the transistor controller where it is distributed to the connect when the EPD switch is pressed, it will
other truck electrical circuits. usually be a short in the EPD switch circuit or a
faulty EPD relay.
A holding circuit must be provided to keep the EPD
relay and EPD contactor energized, otherwise when 3. If the EPD Contactor does not open when the bat-
the EPD Energize switch is released, these circuits tery is disconnected, the EPD contactor should be
would deenergize again opening the EPD contactor replaced. You can check to see if the contactor is
and deactivating the lift truck circuits. The EPD switch open as follows:
provides this holding circuit. Note that when the EPD a. Disconnect the battery from the truck.
relay contacts 9 and 6 close applying voltage to the
b. Set multimeter to measure continuity (low
EPD contactor coil, this voltage is also applied to one
resistance)
side of the EPD switch. The voltage passes through
the normally closed contacts of the EPD switch and is c. Connect multimeter across the EPD contac-
applied to EPD relay terminal A. Now when the PUSH tor contacts power (not the coil) and measure
TO ENERGIZE switch is released a complete circuit to the resistance. If resistance is near "0" resis-
the EPD relay still exists keeping the relay energized. tance, the contactor contacts are not open
This path is now from battery positive through the 300 and the contactor is faulty.

4-8 900980
 TO B- ON
TRANSISTOR
CONTROLLER

EPD
SWITCH

CIRCUITS

R6039

Figure 4-3 Simplified Emergency Power Disconnect Circuit

900980 4-9
 R6040A

Figure 4-4 Emergency Power Disconnect Troubleshooting Chart (Sheet 1 of 2)

4-10 900980
 R6040B

Figure 4-4 Emergency Power Disconnect Troubleshooting Chart (Sheet 2 of 2)

900980 4-11
4-6. SMART CHARGER 004978 TROUBLESHOOT- mum output voltage. Incorrect setting of
ING (Trucks Serial Number 334374 to 374092) this potentiometer can cause damage to
the charger or batteries.
The logic flow troubleshooting diagram provides a sim-
plified means of isolating the probable cause for a CAUTION: A jumper is used on the printed circuit
problem by performing steps to obtain a "yes" or "no" logic board for part of the test. This
answer. Three types of blocks are used. Rectangular jumper must be installed with the
boxes with a regular border provide procedural infor- charger disconnected from the AC power
mation. Rectangular boxes with all upper case letters input.
identify a probable fault. Diamond shaped boxes ask
a question to obtain a yes or no answer. By following Refer to Figure 4-5 for a complete schematic of the
the yes and no line the problem is identified. charger. Figure 4-6 provides information for connect-
ing the jumper when necessary. Figure 4-7 is a logic
CAUTION: Do not ever change the setting on the flow troubleshooting guide.
potentiometer on the printed circuit
board. This is factory set to limit maxi-

120 V AC MALE OUTLET

PLUG FLANGED AMMETER
GR

15A CHARGER
FUSE CONNECTOR
CIRCUIT
BREAKER

INDICATOR
LIGHT LOGIC BRD
L HEAT SINK

LOGIC
BOARD
TRANSF

R5962
(120 VAC) AUTOMATIC CHARGER
Figure 4-5 Battery Charger Schematic

JUMPER

R5963 TO CIRCUIT
BREAKER

Figure 4-6 Logic Board Jumper Position

4-12 900980
 NOTES

900980 4-13
 1.Disconnect charger
from battery
2.Connect charger to
AC input power
source

Is Is 24
VDC to 28 Is 24
approximately VDC to 28
48 VAC VDC present
Is indicator YES present across YES Connect battery between input to YES VDC present from YES
light turned on? to charger circuit breaker (two battery positive (+) side
green wires from of circuit breaker
transformer to red wires) and
heat to heatsink?
logic
board? sink?

NO NO NO
NO
Replace transformer Check battery charger
Disconnect charger
output cable and
from AC power source
Is 120 VAC connector for
present across YES Check indicator light continuity, replace or
transformer connection, replace if repair.
faulty Install jumper on circuit Check for faulty
input?
board as shown in circuit breaker,
Figure 3 replace if necessary.

NO
Reconnect charger to
Check input AC fuse AC power source
and check that power
is present from power
source

Is 24
VDC to 28
VDC now present YES Logic board faulty,
at input to circuit replace logic board
breaker?

NO
Faulty diodes, replace
logic board

R5964A

Figure 4-7 Logic Flow Diagram (Sheet 1 of 2)

4-14 900980
 YES Disconnect AC input
power to the charger

Using an ohmmeter, Measure resistance

check resistance from Is resistance YES between side of YES Ammeter faulty
negative side of ammeter connected Is resistance
greater than
connector to chassis to charger and near 0 ohms? replace ammeter
100 Ohms
ground. chassis ground.

NO NO
Check connection
Charger ok
between ammeter
and logic board

R5964B

Figure 4-7 Logic Flow Diagram (Sheet 2 of 2)

900980 4-15
 USED ON TRUCKS
SERIAL NUMBERS
334774 to 356020

15A

LOGIC
BOARD

R5517A

Figure 4-8 Electrical Schematic (Sheet 1 of 2)

4-16 900980
 USED ON TRUCKS
SERIAL NUMBERS
334774 to 356020

R5517B

Figure 4-8 Electrical Schematic (Sheet 2 of 2)

900980 4-17
 USED ON TRUCKS
SERIAL NUMBERS
356021 TO 374092

R6041A

Figure 4-9 Electrical Schematic (Sheet 1 of 2)

4-18 900980
 USED ON TRUCKS
SERIAL NUMBERS
356021 TO 374092

R6041B

Figure 4-9 Electrical Schematic (Sheet 2 of 2)

900980 4-19
 USED ON TRUCKS
SERIAL NUMBERS
334774 to 356020

R5773

Figure 4-10 Wiring Diagram (Sheet 1 of 2)

4-20 900980
 USED ON TRUCKS
SERIAL NUMBERS
334774 to 356020

R5774

Figure 4-10 Wiring Diagram (Sheet 2 of 2)

900980 4-21
 USED ON TRUCKS
SERIAL NUMBERS
356021 TO 374092

R6042A

Figure 4-11 Wiring Diagram (Sheet 1 of 2)

4-22 900980
 USED ON TRUCKS
SERIAL NUMBERS
356021 TO 374092

R6042B

Figure 4-11 Wiring Diagram (Sheet 2 of 2)

900980 4-23
 NOTES

4-24 900980
 SECTION 5
STEERING SYSTEM MAINTENANCE

5-1. GENERAL. 5-2. STEERING CABLE TENSION.

1. Lower lift carriage as far as it will go.
The steering system is engineered to meet the design
requirements of a steering wheel mounted on a mov- 2. Remove the carriage access panel located below
able lift carriage and capable of steering the vehicle the operator controls.
while the lift carriage is in any position. See Figure 5-1 NOTE: Top nut on turnbuckle is right-hand thread.
for a diagram of the steering system. Bottom nut is left-hand thread.
All connections (cables and chains) between the lift
3. Loosen nuts (27 and 29, Figure 5-3) on turnbuck-
carriage and body of the vehicle must remain taut
les (28).
while allowing for movement of the lift carriage. The
steering cable tension is especially critical so that the CAUTION: Overtightening will cause excessive
motion of the steering wheel is transmitted to the cable wear.
steering sheave with minimum delay. This is accom-
plished by routing the steering cables from the lift car- 4. Tighten turnbuckles (28) by hand. The cables
riage to the body over sheaves mounted on the ram should be just tight enough to minimize slack in
head. Since the lift carriage is raised by chains pass- the steering system.
ing over sheaves on the ram head, the steering cables 5. Tighten nuts (27 and 29) against turnbuckles (28).
will be lifted exactly the same amount as the chains.
6. Install the carriage access panel below the opera-
This keeps the steering cables under tension for all the
tor controls.
lift carriage positions.

900980 5-1
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R3120

Figure 5-1 Steering Cable Diagram

5-2 900980
 USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374092

CABLE LOCKING
SCREWS & NUTS

R5880

Figure 5-2 Steering Cable Diagram

900980 5-3
 CABLE KIT
PART NUMBER
900514
CONTAINS:
ITEM QTY
20 31
21 2
26 2

R3121

Figure 5-3 Steering Controls (Sheet 1 of 3)

5-4 900980
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R3122

Figure 5-3 Steering Controls (Sheet 2 of 3)

900980 5-5
 USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374092

R5881

Figure 5-3 Steering Controls (Sheet 3 of 3)

5-6 900980
5-3. STEERING SHEAVE AND PIVOT BUSHINGS. b. Trucks serial number 354287 to 374092,
If the steering sheave or pivot bearing become dam- remove four screws and four washers, then
aged, disassemble for repair or replacement as fol- remove sheave (6) and pivot tube (7) from
lows: transmission.
5. Repair or replace sheave (6).
1. Remove the pivot tube (complete with transmis-
sion, drive wheel and motor). Refer to paragraph 6. Reattach sheave (6) as follows:
5-6.1. a. Trucks serial number 334774 to 354286,
2. Remove flange bushing (13, Figure 5-4) from the secure sheave (6) on tube (7) with four wash-
upper bore. ers (5) and four screws (4).
3. Remove three screws (9) and flange bushing (8) b. Trucks serial number 354287 to 374092,
from the lower bore. place pivot tube (7) over mounting holes in
4. Remove sheave (6) as follow: transmission then align sheave (6) mounting
holes and attach with four screws and four
a. Trucks serial number 334774 to 354286, washers.
remove four screws (4), four washers (5) and
sheave (6) from pivot tube (7).

USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R3123

Figure 5-4 Steering Sheave and Pivot Bushings

900980 5-7
7. Install bushing (8) in the lower bore and secure 2. Locate the steering cable turnbuckles on mast.
with three screws (9). Loosen the nuts and turn the buckles to relieve
8. Install bushing (13) in the upper bore. tension on lower steering cables.

9. Install the transmission (complete with drive 3. Remove nut (34, Figure 5-3) and lock washer (35)
wheel and motor). Refer to paragraph 5-6.2. from screw (33).
4. Remove screw (33), sheave (32) and washer
5-4. SHEAVE ASSEMBLIES. (31).
The sheave assemblies have bearings that are lubri- 5. Position the replacement sheave (32) and washer
cated for life. To replace a sheave, proceed as follows: (31) on screw (33). Secure screw (33) to the vehi-
cle with lock washer (35) and nut (34).
1. Remove the carriage access panel located below
the operator controls. 6. Check that the steering cables are properly posi-
tioned on their sheaves.
NOTE: Top nut on turnbuckle is right-hand thread.
7. Adjust the steering cable tension. Refer to para-
Bottom nut is left-hand thread.
graph 5-2.
8. Install the carriage access panel below the opera-
tor controls.

USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374092

4
5

R5882

Figure 5-5 Steering Sheave and Pivot Bushings

5-8 900980
5-5. STEERING CABLE REPLACEMENT. 8. Wrap the new cable around the main steering
sheave to the hole from which the old cable was
5-5.1. Preliminary Preparation. removed.
1. Place vehicle in an area that provides work space 9. Feed cable through its hole in the sheave and
on all sides. install nuts (27).
2. Turn the drive wheel to a straight position. 10. Adjust the steering cable tension. Refer to para-
3. Block wheels to prevent vehicle from rolling. graph 5-2.
4. Raise carriage to a height of approximately six 5-5.2.2.Trucks Serial Number 354287 to 374092.
feet to be able to work under it.
5. Place strong steel automotive-type supports NOTE: Top nut on turnbuckle is right-hand thread.
under the carriage approximately 24 inches out Bottom nut is left-hand thread.
from the mast. 1. Locate the steering cable turnbuckles on mast.
6. Lower the carriage onto the supports using the lift 2. Loosen nuts (27 and 29, Figure 5-3 (sheet 3 of 3)
controls. then separate the lower cables from the turnbuck-
7. Check that the supports are secure and that the les.
carriage is lowered as far as it will go, but do not 3. Disconnect the steering cables at the steering
allow slack in the lift chains. sheave by loosening the jam nuts (36) then
8. Turn off the key switch and disconnect the battery loosening the screws (37) and (38).
connector. 4. Remove the old steering cable (30) from the
9. Remove the carriage access panel located below truck.
the operator controls. 5. Screw the new lower cable assemblies into turn-
10. Remove the four screws securing the lower chas- buckles (28) until the two parts are just threaded
sis access door and remove the door. together.
6. Thread the lower end of the cable through the
5-5.2. Replacing Lower Steering Cable.
sheaves (32).
5-5.2.1.Trucks Serial Number 334774 to 354287. 7. Wrap the new cable around the main steering
sheave 3/4 turn and insert the end of the cable
NOTE: Top nut on each turnbuckle is right-hand
into the cable access hole.
thread; bottom nut is left-hand thread.
8. Secure cable by tightening screws (37) and (38),
1. Locate the steering cable turnbuckles on mast. then secure screws with jam nuts (36).
Loosen nuts (27 and 29, Figure 5-3) and turn 9. Adjust the steering cable tension. Refer to para-
buckle (28) to relieve tension on the steering graph 5-2.
cables. Separate the lower cable from buckle
(28). 5-5.3. Replacing Upper Steering Cable.
2. Disconnect the steering cable at the steering
NOTE: Top nut on each turnbuckle is right-hand
sheave by loosening two the nuts (27) and sliding
thread; bottom nut is left-hand thread.
the steering cables out of its hole in sheave rim.
3. Remove the old steering cable from the vehicle. 1. Locate the steering cable turnbuckles on mast.
Loosen nuts (27 and 29, Figure 5-3) and turn
4. Lay out old cable along the ground, measure it
buckle (28) to relieve tension on the steering
and cut new cable to this length.
cables. Separate the upper cable from buckle
5. Attach the cable ends (26 and 30) to the cable. (28).
Refer to paragraph 5-5.4.
2. Remove connecting link (19) to free the old cable
6. Screw new lower cable assembly into buckle (28) from chain (18).
until the two parts are just threaded together.
3. Remove the old steering cable from the vehicle.
7. Thread the lower end of the cable through the
4. Lay out old cable along the ground, measure it
sheaves (32).
and cut new cable to this length.

900980 5-9
5. Attach the cable end (26) and eyelet end (21) to 5. Check that the ends of twisted wires appear
the cable. Refer to paragraph 5-5.4. through inspection hole (detail D).
6. Secure the eyelet of the new cable to chain (18) NOTE: Complete cables are shown at the right of
with connecting link (19). Figure 5-6.
NOTE: Check that the steering wheel is in the
5-5.5. Concluding Steps.
desired position.
1. Turn the steering wheel from one stop to the
7. Thread the new cable through the sheaves. other. Be sure that all cable ends are tight and
8. Screw new upper cable assembly into turnbuckle that none of the cable ends touch the sheaves
(28) until the two parts are just threaded together. when the transmission is moved against the
stops.
9. Adjust the steering cable tension. Refer to para-
graph 5-2. 2. If necessary to trim cables, loosen turn buckle
and remove cable. Trim excess cable length and
5-5.4. Attaching Socket Assemblies to Wire Rope. reinstall cable.
The upper and lower steering cables must be cut to 3. Install the carriage access panel below the opera-
the proper length. Use the following procedure to tor controls.
attach the eye or stud socket assemblies, as required, 4. Secure the lower chassis access door with the
to a cut cable end. Refer to Figure 5-6. four screws.
1. Pass wire rope through sleeve (detail A). 5. Reconnect the battery, raise the lift carriage, and
2. Fan out wires for insertion of solid plug (detail B). remove the supports from under it.
3. Drive plug in and close wires over it (detail C). 6. Lower the carriage and unblock wheels to free
4. Thread socket onto sleeve; tighten with wrenches vehicle for normal duty.
(detail D).

R714A,B

Figure 5-6 Assembly of Steering Cables

5-10 900980
5-6. PIVOT TUBE REPLACEMENT. 15. Slowly lower pivot tube and transmission out of
truck chassis and remove ring (12), thrust bearing
5-6.1. Removal. (11), and two rings (15).
1. Disconnect the battery. 16. Remove the pivot tube as follows:
2. Securely block load wheels. a. Trucks serial number 334774 to 354286,
3. Remove the four screws securing the lower chas- remove four screws (57, Figure 5-7), lock
sis access door and remove the door. washers (58) and steering sheave (59) from
pivot tube (49). Remove four screws (50) and
4. Make sure the four cables to the drive motor (1,
pivot tube (49) from transmission (56).
Figure 5-7 or Figure 5-8) are properly labeled A1,
A2, S1, and S2 and then disconnect the cables b. Trucks serial number 354287 to 374092,
from the drive motor. Remove four screws (57, Figure 5-8) and
5. Tag the two wires (26) attached to horn (29) and four lock washers (58) and remove sheave
disconnect the wires and spike suppressor (30). (50) and pivot tube (49) from transmission
Tag and disconnect the two wires (27) from dead- (56).
man switch (28). 5-6.2. Installation.
NOTE: Transmission oil capacity is 3 pints. 1. Attach pivot tube as follows:
6. Remove the drain plug from transmission and a. Trucks serial number 334774 to 354286,
drain the oil. attach pivot tube (49, Figure 5-7) to transmis-
7. Remove screw (22) and free barrel (16) from lever sion with four screws (50). Attach the steer-
(20). ing sheave (59) with four screws (57) and
lock washers (58).
8. Remove spring (11), cotter pin (9) and pin (13).
Move slave cylinder (15) out of the way. b. Trucks serial number 354287 and higher,
attach pivot tube (49, Figure 5-8) and steer-
9. Remove the carriage access panel located below ing sheave (50) to transmission with four
the operator controls. screws (57) and four washers (58).
NOTE: Top nut on turnbuckle is right-hand thread. 2. Position the pivot tube and transmission assem-
Bottom nut is left-hand thread. bly under the truck chassis and carefully insert the
pivot tube up into the pivot tube weldment while
10. Locate the steering cable turnbuckles on mast.
installing two rings (15, Figure 5-4 or Figure 5-5)
Loosen the nuts and turn the buckles to relieve
thrust bearing (11) and ring (12) on the tube.
tension on lower steering cables.
3. Align the holes of rings (15) with the holes in tube
11. Disconnect the steering cables as follows: (7) and install pins (10) and cotter pins (14).
a. Trucks serial number 334774 to 354286, 4. Position cap (2) on end of tube (7) and secure
remove two nuts (27, Figure 5-2, Sheet 2) with screws (1).
and remove cables (30) from the steering
sheave. 5. Remove the blocking and lower the vehicle to the
ground.
b. Trucks serial number 354287 to 374092,
6. Connect lower steering cable as follows:
remove two screws (37 and 38, Figure 5-2,
Sheet 3) and two nuts (36) and remove a. Trucks serial number 334774 to 354286,
cables (30) form the steering sheave. reconnect the two steering cables (30, Figure
5-3, sheet 2) to the sheave and secure with
12. Raise the truck off the drive wheel with jacks or
two nuts (27).
other suitable means. Place blocks under the
truck and remove the jacks. b. Trucks serial number 354287 to 374092,
13. Remove two cotter pins (14, Figure 5-4 or Figure reconnect the two lower steering cables (30,
5-5) and two pins (10). Figure 5-3, Sheet 3) and secure with the two
screws (37 and 38) then lock down with jam
14. Support tube (7) with attached transmission and nuts (36).
remove two screws (1) and cap (2).
7. Check that the steering cables are properly posi-
tioned on their sheaves.

900980 5-11
8. Adjust the steering cable tension. Refer to para- 12. Reconnect the four cables to the drive motor (1).
graph 5-2. 13. Reconnect the two wires (26) and spike suppres-
9. Position slave cylinder (15, Figure 5-7 or Figure 5- sor (30) to horn (29). Reconnect the two wires
8) in bracket (12) and install pin (13), cotter pin (9) (27) to deadman switch (28).
and spring (11). 14. Reconnect the battery.
10. Secure barrel (16) to lever (20) with screw (22). 15. Secure the lower chassis access door with the
NOTE: Transmission oil capacity is 3 pints. four screws.
16. Remove the blocks from the load wheels.
11. Reinstall the transmission drain plug and fill the
transmission with oil to the proper level.

USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R5757

Figure 5-7 Transmission, Brake and Motor Assembly

5-12 900980
 USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374092

R5879

Figure 5-8 Transmission, Brake and Pivot Tube Assembly

900980 5-13
 NOTES

5-14 900980
 SECTION 6
BRAKE SERVICING

6-1. GENERAL 7. When all air has been removed and clear system
The chassis mounted parts of the brake system are fluid is observed, close the actuator bleeder and
shown in Figure 6-1 or Figure 6-2 and the carriage then the slave cylinder bleeder.
mounted parts are shown in Figure 6-3. 8. Close the pressure bleeder valve and remove the
bleeder from the reservoir.
6-2. BRAKE DEADMAN SWITCH
NOTE: Use hydraulic oil only in brake system.
The brake deadman switch is mounted on the trans-
mission. Proceed as follows to check and adjust the 9. Refill reservoir as needed. Do not allow reservoir
switch: to completely empty.
1. Remove the four screws securing the lower chas- 10. Install the carriage access panel below the opera-
sis access door and remove the door. tor controls.
2. With the brake pedal in the raised position, check 11. Secure the lower chassis access door with the
that the tab of lever (20, Figure 6-1 or Figure 6-2) four screws.
depresses the button of switch (28), but does not
touch the switch bushing. 6-4. BRAKE HOSE REPLACEMENT
3. If the tab of lever (20) does not depress the switch The brake hose is adjusted by loosening the brake
button, loosen the switch mounting bolts and hose clamps, taking the slack out of the hose then
move switch (28) toward lever (20), then tighten retightening the hose clamps
the mounting bolts.
6-5. BRAKE ADJUSTMENT
4. If the tab of lever (20) depresses the switch button
and also touches the switch bushing, loosen the 1. Block the load wheels to prevent the vehicle from
switch mounting screws and move the switch moving.
slightly away from lever (20), then tighten the 2. Turn off the key switch and disconnect the battery
mounting bolts. connector.
5. Check actuation of brake deadman switch by lis- 3. Remove the four screws securing the lower chas-
tening for the audible click as the brake pedal is sis access door and remove the door.
depressed and again as the brake pedal is
released. 4. Jack up the vehicle so drive wheel (53, Figure 6-1
or Figure 6-2) is off the ground and securely block
6. Secure the lower chassis access door with the the vehicle.
four screws.
5. When the brake pedal is released, (UP), the
brake should grab firmly enough so the disc (3)
6-3. BLEEDING THE BRAKE SYSTEM
cannot be turned by hand. Tighten nut (8) to
1. Remove the carriage access panel located below increase braking force.
the operator controls.
6. Depress the brake pedal. If the brake does not
2. Remove the four screws securing the lower chas- fully release disc (3), remove shoulder bolt (22)
sis access door and remove the door. and partially unscrew brake barrel (16) out on
3. Set the pressure bleeder at approximately 20 PSI. slave cylinder rod. Reconnect linkage and test
again.
4. Attach the bleeder hose connector to the reservoir
(1, Figure 6-3). 7. If additional adjustment is necessary or if the
brake pedal (5, Figure 6-3) cannot travel to the
5. Open the bleeder screws at both actuator (3) and
floor, loosen the jam nut on actuator (3) and turn
slave cylinder (15, Figure 6-1 or Figure 6-2).
rod to increase or decrease pedal height.
6. Open the bleeder screw on the pressure bleeder.

900980 6-1
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R5757

Figure 6-1 Transmission, Brake and Motor Assembly

6-2 900980
 USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374093

R5879

Figure 6-2 Transmission, Brake and Pivot Tube Assembly

900980 6-3
 R5749

Figure 6-3 Chassis Brake Components

8. Continue adjustments until full brake engagement 2. Turn off the key switch and disconnect the battery
and release is observed with up and down pedal connector.
movement. 3. Remove the four screws securing the lower chas-
9. Lower the vehicle to the ground. sis access door and remove the door.
10. Adjust the brake deadman switch. Refer to para- 4. Remove jam nut (8, Figure 6-1), lock washer (33),
graph 6-2. rod (10), spring (11), cotter pin (19) and clevis pin
11. Bleed the brake system. Refer to paragraph 6-3. (17).

12. Install the access door with the four screws. 5. Remove cotter pin (9) and free clevis (18) from
lever (46).
13. Reconnect the battery.
6. Remove two nuts (36) and lock washers (37).
14. Unblock the wheels.
7. Carefully pull bolts (42) just enough to clear the
15. When properly adjusted, the brake should stop bracket (7) while holding together the remaining
the truck, loaded to rated capacity and traveling at parts of the disc brake assembly (35), then
top speed, within 6 feet. If the brake cannot be remove the assembly.
bought into proper adjustment, the brake system
may require bleeding. Refer to paragraph 6-3. 8. Remove bolts (42), spacers (39), springs (40),
and brake pad (41).
6-6. REPLACEMENT OF DISC BRAKE PARTS 9. Remove C-ring (43), washer (44), spring (45),
1. Block the wheels to prevent the vehicle from mov- bracket (38), lever (46), and washer (47) from the
ing. brake pad (48).

6-4 900980
10. Discard springs (40 and 45) and brake pads (41 14. Insert bolts (42) through pad (48) and bracket
and 48). Also discard any other parts that are (38), so the threaded portion of the bolts pass
worn or damaged. Replace parts with new. completely through.
11. Assemble washer (47). lever (46), bracket (38), 15. Assemble lock washer (37) and nuts (36) on bolts
spring (45), washer (44), and C-ring (43) to the (42).
brake pad (48). 16. Engage clevis (18) with the lever (46), then
12. Assemble brake pad (41), springs (40), and spac- secure with cotter pin (9).
ers (39) to the two bolts (42). 17. Reassemble clevis pin (17), cotter pin (19), spring
13. Slip the parts assembled in step 11. onto bracket (11), rod (10), lockwasher (33) and jam nut (8).
(7) and hold them so the bolt holes are aligned. 18. Adjust the brake. Refer to paragraph 6-5.

900980 6-5
 NOTES

6-6 900980
 SECTION 7
TRANSMISSION, DRIVE WHEEL, AND LOAD WHEEL SERVICING

7-1. TRANSMISSION REMOVAL 6. Remove cotter pin (9), pivot pin (23), and lever
1. Remove the pivot tube (complete with transmis- (20) from bracket (24).
sion, drive wheel and motor). Refer to SECTION 5 7. Remove the two screws (31), lock washers (33),
horn (29), and bracket (24) with switch (28) from
2. Remove the five hex head screws (51, Figure 7-1
transmission (56).
or Figure 7-2) and lock washers (52) that secure
the drive wheel (53) to the axle shaft and then 8. Remove two screws (32), lock washers (33), and
remove the wheel. block (12) from transmission (56).
3. Remove nut (8), lock washer (33), rod (10), and 9. Position the drive assembly to access the two
spring (11). screws (24, Figure 7-3) and washers (18) which
secure the motor (38) to the transmission (31)
4. Remove cotter pin (9) and free clevis (18) from
and remove the screws and washers.
lever (46).
10. Reposition the drive assembly to allow the motor
5. Remove cotter pin (19), clevis pin (17), clevis (18)
to be pulled out through the access opening.
and bushing (21) from lever (20).

USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R5757

Figure 7-1 Chassis Brake Components

900980 7-1
 USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374093

R5879

Figure 7-2 Chassis Brake Components

7-2. TRANSMISSION REPAIR 8. Remove locknut (8) and lock washer (7).
1. Remove the transmission. Refer to paragraph 7- 9. Remove drive wheel and axle shaft (1) to free
1. gear (6), roller bearing cones (3) and cups (4),
2. Remove the four hex head cap screws (22, Figure and oil seal (2).
7-3) and lock washers (23), bearing cover (21) 10. Remove ball bearing (9).
and gasket (20). 11. Refer to the disassembly instruction as a guide,
3. Remove bearing spacer (15). and reverse the individual procedures of steps 10
through 1 to reassemble and reinstall the trans-
4. Remove seven screws (19), two screws (25), and
mission.
lock washers (18); pry off transmission cover (17)
and pull off cover gasket (16). NOTE: Transmission oil capacity is 3 pints.
5. Remove ball bearing (14) and pinion spacer (13).
12. Fill the transmission to fill plug level with No. 80
6. Remove intermediate gear (12) and square key automotive transmission oil.
(10).
7. Remove spur pinion (11).

7-2 900980
 R3164

Figure 7-3 Transmission

7-3. TRANSMISSION INSTALLATION 8. Install wheel (53) with the five hex head screws
(51) and lock washers (52).
1. Secure drive motor (38, Figure 7-3) to transmis-
sion (31) with two screws (24) and washers (18). 9. Install the pivot tube (complete with transmission,
2. Position block (12, Figure 7-1 or Figure 7-2) on drive wheel and motor). Refer to SECTION 5.
transmission (56) and secure with lock washers 10. Check brake adjustment. Refer to SECTION 6.
(33) and screws (32).
7-4. DRIVE WHEEL REPLACEMENT
3. Position bracket (24) and horn (29) on transmis-
sion (56) and secure with lock washers (33) and 1. Remove the pivot tube (complete with transmis-
screws (31). sion, drive wheel and motor). Refer to SECTION
4. Position lever (20) in bracket (24) and install pivot 5.
pin (23) and cotter pins (9). 2. Remove the five hex head screws (51, Figure 7-1
5. Insert bushing (21) in lever (20). Connect clevis or Figure 7-2) and lock washers (52) that secure
(18) to lever (20) with clevis pin (17) and cotter pin the drive wheel (53) to the axle shaft and then
(19). remove the wheel.

6. Position clevis (18) in lever (46) and secure with 3. Install the replacement wheel (53) with the five
cotter pin (9). hex head screws (51) and lock washers (52).

7. Install spring (11), rod (10), lock washer (33), and 4. Install the pivot tube (complete with transmission,
nut (8). Adjust nut (8) to put tension on spring drive wheel and motor). Refer to SECTION 5.
(11).

900980 7-3
 7-5. LOAD WHEEL REPLACEMENT 8. Remove snap ring (1, Figure 7-4) from axle (2).
1. Unload the vehicle and lower the platform as far 9. With a large punch and a hammer, drive the axle
as it will go. out, being careful not to damage the axle.
2. Position the vehicle on level floor and block the NOTE: There is one washer (4) on each side of the
drive wheel to prevent vehicle movement. wheel.
3. Using an automotive jack or fork lift, lift the strad-
10. Lift the wheel (5) out from the top. Locate and
dle of the vehicle about 5 or 6 inches, position
remove washers (4) that were on the axle.
blocks under the straddle, and lower the straddle.
4. Raise carriage to a height of approximately three 11. To replace a wheel, partially insert the axle (2)
feet. and place a washer (4) on the end inside the
straddle.
5. Place strong steel automotive-type supports
12. Lower the new wheel into the housing and slowly
under the carriage approximately 24 inches out
withdraw the axle until it clears the wheel, permit-
from the mast.
ting the wheel to be lowered into position, then
6. Lower the carriage onto the supports using the lift push the axle through the wheel, lower a washer
controls. on the other side, and engage with axle.
WARNING: Do not put fingers or toes under the 13. Secure axle with snap ring (1).
straddle at any time. 14. Return the vehicle to working condition.
7. Turn off the key switch and disconnect the battery
connector.

R3126

Figure 7-4 Load Wheel

7-4 900980
 SECTION 8
ELEVATION SYSTEM SERVICING

8-1. GENERAL 10. Reassemble by reversing the disassembly proce-

The elevation system includes the mast, lift chains, lift dure.
cylinder, and ram head.
8-3. LIFT CHAIN ADJUSTMENT
8-2. RAM HEAD REPLACEMENT WARNING: Before attempting any adjustment make
1. Place vehicle on level surface. certain power is disconnected.
2. Block wheels to prevent vehicle from rolling. NOTE: Adjusting chain length may affect steering
3. Raise carriage to a height of approximately three cable, brake hose and electrical cable adjust-
feet. ments.
4. Place strong steel automotive-type supports 1. Lower lift carriage as far as it will go.
under the carriage approximately 24 inches out
2. Turn off the key switch and disconnect the
from the mast.
battery connector.
5. Lower the carriage onto the supports using the lift
3. Open the carriage access panel (2, Figure 8-3).
controls.
4. Determine which of the two chains is slack and
6. Model SSCM 20-130 Telescopic: Place steel
must be tightened.
blocks under the bottom edges of the inner mast
to support it solidly. 5. Loosen nut (20, Figure 8-1 or Figure 8-2) on
adjusting bolt (19)
7. Check that the supports are secure and that the
carriage is lowered as far as it will go. 6. Turn nut (22) until the chains are equally tight.
8. Turn off the key switch and disconnect the 7. Tighten nut (20).
battery connector. 8. Check and adjust tension of steering cable (SEC-
TION 5), brake hose adjustment (SECTION 6),
CAUTION: All sheaves except the chain sheaves
and electrical cable (SECTION 10).
come off when the screws (4, Figure 8-1
or Figure 8-2) are removed. 9. Install carriage access panel (2, Figure 8-3).

9. Remove screws (4) and completely disassemble

as indicated in the illustration.

900980 8-1
 R5750

Figure 8-1 Elevation System (SSCM 20-67)

8-2 900980
 R5751

Figure 8-2 Elevation System (SSCM 20-130)

900980 8-3
 R5752

Figure 8-3 Lift Carriage

8-4. LIFT CHAIN WEAR INSPECTION 3. Raise carriage to a height of approximately three
Both lift chains should be replaced when either chain feet.
is worn enough to increase it's length by 3% or more. 4. Place strong steel automotive-type supports
To make their determination proceed as follows. under the carriage approximately 24 inches out
from the mast.
Using a section of chain that sees the most frequent
operation over the chain sheaves, isolate a vertical 5. Lower the carriage onto the supports using the lift
portion under tension from the weight of carriage and controls.
forks. 6. Model SSCM 20-130 Telescopic: Place steel
For chain part #402034: Measure the distance blocks under the bottom edges of the inner mast
between pin centers on 20 vertical links. If the section to support it solidly.
measures 12.88" or more, the chain should be 7. Check that the supports are secure and that the
replaced. carriage is lowered as far as it will go.
New chain anchor pins should be installed when WARNING: Before attempting any actual replace-
chains are replaced. Never replace a partial section of ment, make certain power is discon-
chain and never repair a damaged chain. Refer to nected.
paragraph 8-5 when installing new chain.
8. Turn off the key switch and disconnect the
8-5. LIFT CHAIN REPLACEMENT battery connector.
1. Place vehicle on level surface. 9. Remove the cotter pin (17 Figure 8-1 or
Figure 8-2) and clevis pin (18) from end of chain
2. Block wheels to prevent vehicle from rolling.
connected to mast cross brace.

8-4 900980
10. Remove the cotter pin (17) and clevis pin (17) CAUTION: The lift cylinder is very heavy.
from end of chain connected to lift carriage.
16. Raise the lift cylinder (30) up and out of the mast.
11. Remove chain from sheave (9) and lay aside for
repair. 17. Position the new or repaired lift cylinder in the
mast.
12. Position new chain in place on sheave.
18. Reinstall clamp (16), two lock washers (15) and
13. Connect end of chain to lift carriage adjusting bolt two nuts (14).
(19) with the clevis pin (18) and cotter pin (17).
19. Secure the bottom of the lift cylinder with screw
14. Connect end of chain to chain anchor on mast (28), lock washer (15), and washer (29).
cross brace with the clevis pin (18) and cotter pin
(17). 20. Reconnect pressure hose (19, Figure 12-14) and
overflow tube (6) to the cylinder.
15. Adjust lift chain. Refer to paragraph 8-3.
21. Refill hydraulic reservoir (4).
8-6. LIFT CYLINDER REPLACEMENT 22. Reconnect battery, turn on key switch, and acti-
vate lift control to raise cylinder to ram head.
1. Place vehicle in an area that provides work space
on all sides. 23. Secure top of lift cylinder ram head (10,
2. Block wheels to prevent vehicle from rolling. Figure 8-1 or Figure 8-2) with screw (11)
and lock washer (12).
3. Raise carriage to a height of approximately three
24. Remove the chains securing the ram head to the
feet.
mast.
4. Place strong steel automotive-type supports
25. Raise the lift carriage and remove the supports.
under the carriage approximately 24 inches out
from the mast. 26. Remove the blocks from the wheels.
5. Lower the carriage onto the supports using the lift
controls. 8-7. LIFT CARRIAGE REMOVAL

6. Model SSCM 20-130 Telescopic: Place steel 1. Place vehicle on level surface.
blocks under the bottom edges of the inner mast 2. Block wheels to prevent vehicle from rolling.
to support it solidly. 3. Raise carriage to a height of approximately three
7. Check that the supports are secure and that the feet.
carriage is lowered as far as it will go. 4. Place strong steel automotive-type supports
8. Turn off the key switch and disconnect the under the carriage approximately 24 inches out
battery connector. from the mast.
9. Chain the ram head (10, Figure 8-1 or Figure 8-2) 5. Lower the carriage onto the supports using the lift
to the mast to support it during cylinder removal. controls.
10. Place any container suitable for catching a few 6. Model SSCM 20-130 Telescopic: Place steel
pints of oil under elbow (12, Figure 8-1 or Figure blocks under the bottom edges of the inner mast
8-2). to support it solidly.
11. Disconnect hose (19) and allow hose to drain into 7. Check that the supports are secure and that the
container. carriage is lowered as far as it will go.
12. Disconnect overflow tube (6). WARNING: Before attempting any actual replace-
13. Remove screw (28, Figure 8-1 or Figure 8-2), lock ment, make certain power is discon-
washer (15), and washer (29) from the bottom of nected.
the lift cylinder.
8. Turn off the key switch and disconnect the
WARNING: Keep fingers out of the way of the cylin- battery connector.
der as it descends when free. 9. Remove two screws (2, Figure 8-1 or Figure 8-2)
14. Remove screw (11) and lock washer (12). and lock washers (1) from the top of the mast.

15. Remove two nuts (14), two lock washers (15) and 10. Remove the cotter pin (17) and clevis pin (18)
clamp (16). from end of chain connected to lift carriage.

900980 8-5
11. Remove lift carriage from mast using a chain 4. Installation of the mast is performed in the reverse
hoist. order of removal.
12. Installation of new or modified lift carriage is per- 5. Lubricate the newly installed mast. Refer to para-
formed in the reverse order of removal. graph 8-10.
13. Adjust lift chain. Refer to paragraph 8-3.
8-10.MAST LUBRICATION PROCEDURE
8-8. LIFT CARRIAGE DISASSEMBLY Fully lower the lift carriage
Refer to Figure 8-3 as a guide in disassembly and to 1. Apply a Lithium base general purpose grease
identify replacement parts. using a lubrication gun, to the grease fittings of
the following components:
8-9. INNER MAST REMOVAL (SSCM 20-130)
a. Outer-mast rollers
1. Remove the lift carriage. Refer to paragraph 8-7.
b. Chain sheaves
CAUTION: Before disconnecting any hydraulic lines, c. Inner mast rollers
make certain the system is not under
pressure. Refer to Section 9. d. Lift carriage rollers
2. Apply a Lithium base general purpose grease with
2. Remove lift cylinder. Refer to paragraph 8-6.
a brush to the full length of masts where rollers
3. Use a chain hoist to remove the inner mast (35, touch.
Figure 8-2) from chassis frame.
8-11.BASE AND FRAME
CAUTION: Do not lean mast against wall or where it
may accidentally fall or be hit. Refer to Figure 8-4 as a guide in disassembly and to
identify replacement parts.

8-6 900980
 R3127

Figure 8-4 Base and Frame

900980 8-7
 NOTES

8-8 900980
 SECTION 9
HYDRAULIC SYSTEM SERVICING

9-1. GENERAL. pressure causes the relief valve to open, and allows
Primary components of the hydraulic system (Figure the oil to flow back into the reservoir.
9-1) are the reservoir, filter, pump, relief valve, lift cylin- Trucks without the optional carriage operated manual
der, flow control valve, hangup valve, and manual lowering system will have a release valve (43, Figure
release valve. Depressing the lift pushbutton applies 9-2) located next to the pump motor. Components for
battery voltage to the pump motor relay, energizing it the standard hydraulic system are shown in Figure 9-
to start the pump motor. The pump then draws hydrau- 2. Components for the optional carriage operated
lic oil from the reservoir through the hangup valve and manual lowering system are shown in Figure 9-5.
flow control valve to the hydraulic lift cylinder. The
pump continues to function, and the cylinder lifts the 9-2. RELIEVING SYSTEM PRESSURE.
platform until the lift pushbutton is released or the plat-
form reaches its maximum height. WARNING: Hydraulic system pressure must be
relieved before removing hydraulic sys-
Depressing the lower pushbutton applies battery volt- tem components. Use the following pro-
age to the solenoid valve on the pump. This permits cedure to relieve system pressure:
the hydraulic oil to flow back from the lift cylinder,
through the flow control, hangup valve, and solenoid 1. Fully lower the lift carriage unless the procedure
valve back into the reservoir, letting the platform for a component directs differently.
descend. The flow control valve is preset to the maxi- 2. Disconnect battery.
mum desirable lowering speed. The hangup valve is a
safety device. This valve is operated by the hydraulic CAUTION: Use rags and a suitable container to
pressure applied to it by the weight of the descending catch any dripping oil when the hydraulic
platform. If the platform strikes an obstruction while lines are disconnected. Wipe off any
descending and hangs up on the obstruction, the spilled oil immediately.
decrease in hydraulic pressure causes the valve to
close. This stops the downward motion of the cylinder 3. Obtain a suitable container to catch any oil that
and mast, preventing the chains and cables from com- may escape when opening a line.
ing loose. The relief valve is set to provide sufficient 4. Open the low pressure line at any convenient
hydraulic pressure to lift the rated load, but excessive connection near the component that is to be
repaired or replaced.

R3156

Figure 9-1 Hydraulic Schematic Drawing

900980 9-1
9-3. HYDRAULIC PRESSURE ADJUSTMENT. 3. Activate pump motor until cylinder hits stop and
observe reading on pressure gauge. If pressure
WARNING: Improper setting of the hydraulic pres- reading is 1575 psi, the relief valve is functioning
sure by an unauthorized person can void properly and does not need adjustment. Deacti-
your Big Joe guarantee. vate pump motor. Lower completely. Disconnect
The relief valve is factory set to open beyond the rated gauge, and reconnect pressure hose. If pressure
capacity of the system and rarely needs adjusting. If reading is above or below 1575 psi, proceed to
you suspect that the relief valve is malfunctioning, per- adjust the relief valve as follows:
form the following procedures: CAUTION: Do not set pressure too high or lift
CAUTION: A pressure gauge must be used. assembly and hydraulic system may be
damaged.
1. Lower lift carriage as far as it will go.
4. Back off lock not of adjusting screw on relief valve
2. Disconnect hose (20, Figure 9-2) at tee (21) and (39).
connect a pressure gauge of adequate range (0-
3000 psi) to tee(21). 5. Adjust screw for a pressure indication of 1575 psi.
6. Tighten lock nut to prevent adjusting screw from
turning.

R5753

Figure 9-2 Hydraulic System

9-2 900980
9-4. LINE, FITTING AND HOSE REPLACEMENT. 4. Remove plug (49, Figure 9-2) and drain the
hydraulic oil from reservoir (4) into a clean bucket
NOTE: Leaking hydraulic fittings can sometimes be or suitable container.
remedied by simply tightening the fitting. If
this does not remedy the leak, the fitting or 5. Loosen clamp (32) and disconnect suction hose
line must be replaced. A leak in the suction (33) from nipple (53).
line between the pump and the reservoir will 6. Trucks serial number 334774 to 357009:
sometimes cause hydraulic oil to foam Remove nuts (52) and hold down plate (51).
through the vent. 7. Remove filter (50).
WARNING: Before disconnecting any hydraulic lines, 8. Trucks serial number 334774 to 357009:
make certain the system is not under Remove O-ring (7) from filter (50).
pressure. Refer to paragraph 9-2.. 9. Clean or replace filter (50).
1. Remove reservoir drain plug (49, Figure 9-2) and 10. Trucks serial number 334774 to 357009: Install
drain hydraulic oil into a suitable container. new O-ring (7) on filter (50).
2. Remove the leaking line or fitting and replace it 11. Reinstall filter (50).
with a new one. Refer to Figure 9-2. 12. Trucks serial number 334774 to 357009: Install
3. Clean the drain plug thoroughly. plate (51) with nuts (52).
4. Reinstall the drain plug. 13. Reattach hose (33) to nipple (53) with clamp (32).

NOTE: Refill only with Big Joe hydraulic oil, and only 14. Refill the hydraulic reservoir.
while the lift carriage is completely lowered.
Refill until oil is to the “FULL” mark on the dip 9-6. HANG-UP VALVE REPLACEMENT.
stick. Refer to Section 3 for oil capacities. 1. Lower the lift carriage as far as it will go.
5. Remove the reservoir vent cap, fill the reservoir to 2. Turn off key switch and disconnect the battery
the “FULL” mark on the dip stick, and replace the connector.
vent cap. 3. Open the upper compartment door.
6. Reconnect battery.
NOTE: A small funnel with a few feet of 1/2 inch
7. Operate the hydraulic controls and check for hose will facilitate draining oil from the reser-
leaks. voir.

9-5. SUMP FILTER REPLACEMENT. 4. Remove plug (49, Figure 9-2) and drain the
hydraulic oil from reservoir (4) into a clean bucket
1. Lower the lift carriage as far as it will go. or suitable container.
2. Turn off key switch and disconnect the battery 5. Disconnect hose (19) at elbow (12) at valve (13).
connector.
6. Remove elbow (12) from valve (13).
3. Open the upper compartment door.
7. Remove valve (13) from nipple (18) and install
NOTE: A small funnel with a few feet of 1/2 inch hose new valve with arrow pointing toward elbow (12).
will facilitate draining oil from the reservoir. 8. Reinstall elbow (12) and reconnect hose (19).
9. Refill the hydraulic reservoir.

900980 9-3
9-7. HYDRAULIC PUMP AND MOTOR ASSEMBLY. WARNING: Before disconnecting any hydraulic lines,
make sure the system is not under pres-
The hydraulic pump and motor assembly can be
sure.
replaced as a unit. Portions of the hydraulic pump and
motor assembly may be repaired. A new set of 6. Disconnect hose (19 and 32) at the pump.
brushes may be installed in the motor or the motor can
7. Remove hose (26) from the pump.
be rebuilt. However, a defective pump has to be
replaced as a complete unit. If the hydraulic pump and 8. Remove the four nuts (56) and four washers (28)
motor is disassembled, the gasket (3, Figure 9-3) must and remove the pump and motor assembly from
be replaced. the vehicle.
1. Lower the lift carriage as far as it will go. 9. Remove the two screws (29) and two washers
(28) and remove plate (30) from the pump and
2. Turn off key switch and disconnect the battery
motor assembly.
connector.
10. If the pump and motor assembly or the pump are
3. Open the upper compartment door.
to be replaced, remove the fittings from the pump
NOTE: A small funnel with a few feet of 1/2 inch hose and reinstall in the new assembly.
will facilitate draining oil from the reservoir. 11. If the pump and motor are to be separated, refer
to Figure 9-3.
4. Remove plug (49, Figure 9-2) and drain the
hydraulic oil from reservoir (4) into a clean bucket 12. If the motor is to be disassembled, refer Section
or suitable container. 10.
5. Tag and disconnect the electrical leads from the 13. Reassemble and reinstall in vehicle by reversing
pump and motor assembly. the sequence of the disassembly procedure.

R3125

Figure 9-3 Hydraulic Pump and Motor Assembly

9-4 900980
 NOTES

900980 9-5
9-8. LIFT CYLINDER REPAIR. NOTE: Cylinders equipped with piston (8), install ret-
rofit kit 907122.
CAUTION: Use proper pipe clamp type vise to
secure the cylinder. The cylinder will be NOTE: Cylinders equipped with piston (14), install
distorted if the vise is tightened too packing kit 907121.
much.
9. Inspect piston (8), rod (5), jackstop (6), and gland
1. Secure lift cylinder in a vise and remove gland nut nut (3) for scores, cracks, or deep scratches.
(3, Figure 9-4) from cylinder tube (1). 10. Coat seal (15) and piston (14) liberally with petro-
2. Remove O-ring (4) and wiper ring (2) from gland leum jelly. Install new seal (15) on piston (14).
nut (3). 11. Install new O-ring (7), piston (14) and nut (11)
3. Pull cylinder rod (5) out of tube (1). onto cylinder ram (5).

CAUTION: Use proper pipe clamp type vise with 12. Remove cylinder ram (5) from vise.
nonmarring jaws to prevent damaging CAUTION: To prevent cylinder damage, use proper
the finish on the rod. pipe clamp type vise. The cylinder will be
4. Secure cylinder rod (5) in vise. distorted if the vise is tightened too
much.
5. Remove nut (11)
6. Trucks serial number 334774 to 351487: 13. Secure lift cylinder tube (1) in vise.
Remove washer (10), and washer (13) from rod 14. Install cylinder ram (5) into cylinder tube (1).
(5). 15. Install new O-ring (4) and wiper (2) on gland (3).
7. Remove piston (8 or 14), O-ring (7), and jackstop 16. Install gland nut (3) in cylinder tube (1).
(6) from rod (5).
17. Remove cylinder from vise.
8. Trucks serial number 334774 to 351487:
Remove packing set (9) from piston (8).

Trucks serial number 351487 to 374093:

Remove seal (15) from piston (14).

9-6 900980
 USED ON TRUCKS
SERIAL NUMBERS
351487 AND BELOW
ORDER RETROFIT
KIT 907122
R6107

RETROFIT KIT
907122
CONTAINS:
ITEM QTY
2 1
4 1
7 1
11 1
14 1
15 1

PACKING KIT
907121
CONTAINS:
ITEM QTY
2 1
4 1
7 1
11 1
15 1

R6106

Figure 9-4 Lift Cylinder Assembly

900980 9-7
9-9. MANUAL LOWERING COMPONENTS. Tee (21, Figure 9-2). Manual release valve (43) is not
installed on trucks using the carriage operated manual
The components used in the carriage manual lowering
lowering system.
system are shown in Figure 9-5. Hose (35) connects to

R3165

Figure 9-5 Carriage Operated Manual Lowering Components

9-8 900980
 SECTION 10
ELECTRICAL COMPONENTS

10-1.DIRECTIONAL SWITCH. 2. Remove parts (2, 3 and 4), then parts (5 thru 9) as
an assembly.
10-1.1.Removal.
3. Remove spacer (10).
For removal of the directional switch refer to Figure
4. Remove two screws (17).
10-4.
5. Remove housing (11), return spring (12) and
10-1.2.Disassembly for Trucks Serial Numbers cover (13).
334774 To 351122.
6. Spray lubricant around shaft of potentiometer
NOTE: Screws (2, Figure 10-1) and washers (3 and (16).
4) are used to mount the directional switch 7. Pressing on the shaft, force potentiometer (16)
assembly in the truck. Nut (1) is used for out of cam (14).
shipping purposes only.
8. Remove any traces of lubricant.
1. Pry switch (7) out of handle (6). Remove wires as 9. Reassembly in the reverse order.
necessary.

USED ON TRUCKS
SERIAL NUMBERS
334774 TO 351122

R5303

Figure 10-1 Directional Switch Assembly

900980 10-1
10-1.3.Disassembly for Trucks Serial Numbers 7. Pull gear (12) off shaft of potentiometer (15).
351123 TO 374092. 8. Remove nut (13) and lock washer (14) from
NOTE: Screws (2, Figure 10-2) and washers (3 and potentiometer (15).
4) are used to mount the directional switch 9. Reassembly in the reverse order.
assembly in the truck. Nut (1) is used for
shipping purposes only. 10-2.ELECTRICAL CABLE MAINTENANCE.

1. Pry switch (7) out of handle (6). Remove wires as 10-2.1.Tension Adjustment.
necessary.
1. Raise life carriage to gain access to electrical
2. Remove parts (2, 3 and 4), then parts (5 thru 9) as cable tension bracket (5, Figure 10-3) mounted on
an assembly. the base of the stock selector.
3. Remove spacer (10). 2. Block lift carriage in raised position to prevent
4. Remove potentiometer male contacts from con- accidental lowering.
nector (16) at locations 5 and 6. 3. Loosen screws on clamp (4) allowing spring (3) to
5. Remove switch assembly (11), including housing, extend to its relaxed position.
return spring and cover. 4. Pull downward on electrical cable (1) from below
6. Loosen nut (13) and pull potentiometer (15) out of to eliminate slack, but do not pull taut.
switch (11), pulling the potentiometer leads free of
the switch.

USED ON TRUCKS
SERIAL NUMBERS
351123 TO 374092

R5758

Figure 10-2 Directional Switch Assembly

10-2 900980
5. Move clamp and spring up to top of bracket (5) 8. Remove the carriage access panel located below
and, while compressing spring, tighten screws on the operator controls.
clamp (4). When released, spring should pull 9. Cut cable wires at terminal board (23, Figure
cable taut. 10-4) leaving sufficient wire to identify wire color
6. If spring and clamp do not move, cable was pulled code.
too taut; if spring expands fully, slack was not 10. Free the cable from strain relief (36) and pull the
removed. Repeat steps 3. through 5. if necessary. cable out of the cable guide.
7. Remove blocks and lower lift carriage. 11. Lift the cable from over the ram head sheave and
lower to ground.
10-2.2.Replacement.
12. Open the upper access door.
1. Move the vehicle to an area suitable for the repair
operation. 13. Cut the cable wires at electrical panel (33, Figure
10-5 or Figure 10-6) leaving sufficient wire to
2. Block the wheels to prevent the vehicle from mov-
identify wire color code.
ing.
14. Cut the cable wires at connector (28) leaving suffi-
3. Raise the carriage to a height of three to six feet
cient wire to identify wire color code.
to be able to work under it.
15. Remove clamps securing cable inside compart-
4. Place strong automotive supports under the car-
ment.
riage approximately 24 inches out from the mast.
16. Pull the old cable out of the compartment.
5. Lower the carriage onto the supports.
17. Remove zipper tubing (26) from the cable.
6. Check that the supports are secure and that the
carriage is lower as far as it will go. 18. Lay out old cable along the ground, measure it
and cut new cable to this length, allowing several
7. Turn off the key switch and disconnect the
extra inches to facilitate fitting and to account on
battery connector.
for lengths of wire cut off during removal.

R3155

Figure 10-3 Control Cable Adjustment

900980 10-3
19. Push the cable through the cable guide. 29. Reconnect the battery connector to restore the
20. Strip off the outer sheathing of the cable. vehicle to normal service.

NOTE: The color coding on the short piece of wire 10-3.ELECTRICAL CONTROL PANEL.
cut from the old cable can be used to insure
proper connection of the new cable. 10-3.1.Adjustment of Controller Potentiometers.
The controller has adjustable plug current, current
21. Connect the cable to terminal board (23, Figure
limit, and acceleration rate settings. Refer to SEC-
10-4) as follows: Match the color of the new cable
TION 4.
wires with the short piece of wire cut from the old
cable. Cut each cable wire to proper length, strip 10-3.2.Panel Replacement.
its end and crimp new terminals to wire ends.
Remove the short piece of wire from the old cable 1. Turn off the key switch and disconnect the battery
and replace with the same color wire of the new connector.
cable. 2. Open the upper access door.
22. Route the length of cable over its sheave on the 3. Tag and disconnect all electrical wires and cables
ram head and down into the compartment. from electrical panel (33, Figure 10-5 or Figure
23. Install the zipper tube over the cable and secure 10-6).
the cable with the clamps previously removed. 4. Remove two nuts (34), lock washers (35), and flat
24. Strip off the outer sheathing of the cable. washers (36) and remove the electrical panel
(33).
NOTE: The color coding on the short piece of wire 5. Install the electrical panel assembly in reverse
cut from the old cable can be used to insure order.
proper connection of the new cable.
10-3.3.Panel Disassembly and Reassembly.
25. Connect the cable to electrical panel (33, Figure
10-5 or Figure 10-6) as follows: Match the color of 1. Refer to Figure 10-7 for identity of components of
the new cable wires with the short piece of wire the electrical panel, and remove defective compo-
cut from the old cable. Cut each cable wire to nents as required.
proper length, strip its end and crimp new termi- 2. Be sure to make note of the location of bussbars
nals to wire ends. Remove the short piece of wire (13), when removing contactors (5), to facilitate
from the old cable and replace with the same reassembly.
color wire of the new cable.
3. Upon reassembly of the electrical panel, inspect
26. Connect cable to connector (28) in the same each electrical connection to ensure that a good
manner. positive contact is made at all wire and cable con-
27. Secure the cable in strain relief (36, Figure 10-4) nections.
28. Close the upper access door and install the car-
riage access panel.

10-4 900980
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 351122

R5661

Figure 10-4 Carriage Mounted Electrical Components

900980 10-5
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 356020

R5660

Figure 10-5 Chassis Mounted Electrical Components

10-6 900980
 USED ON TRUCKS
SERIAL NUMBERS
356021 TO 374092

R6043

Figure 10-6 Chassis Mounted Electrical Components

900980 10-7
 R5519

Figure 10-7 Contactor Panel Assembly

10-8 900980
10-3.4.Contactor Disassembly. 5. Remove nut (12), lock washer (11), flat washer
(10) and contact (13).
1. Remove spring stud (3, Figure 10-8) and spring
(4). NOTE: If only the contacts are to be replaced, no fur-
2. Remove nut (31), lock washer (30), washer (29), ther disassembly is required. Proceed to step
bolt (27), and bus bar (1) (if used).3. Slide back 5 to replace coil.
contact (2) up as far as possible then squeeze
sides of rear molding (28) together and lift off of 6. Remove spacer (14).
frame (19). Separate two sides of rear molding 7. Squeeze sides of front molding (15) and pull for-
and remove back contact (2). ward to disengage from base molding (16).
Remove base molding and remove front molding
3. Remove nut (26) and remove retainer (25) by
from frame (19).
squeezing in on tabs and lifting up.
8. Coil (8) can now be removed from frame (19) by
4. Slide braid assembly (24) off contact (5) and
removing the screw (17) and flat washer (18).
remove contact (5) and armature plate (6) and
spring (4).

CONTACTOR TIP KIT

PART NUMBER
900531-09
CONTAINS:
ITEM QTY
2 1
5 1
13 1
24 1
25 1

R3110

Figure 10-8 Double Pole Contactor

900980 10-9
10-3.5.Contactor Reassembly. motor 901547 is installed as original equipment on
trucks serial number 342087 to 374092.
1. Place the bolt (9, Figure 10-8) through bottom of
front molding (15) and slide molding onto frame NOTE: Removal procedures are covered in SEC-
(19). TION 8.
2. Attach coil (8) to frame (19) with flat washer (18)
and screw (17). Be sure braid assembly (24) has Refer to applicable Figure 12-24, Figure 12-25 or Fig-
been attached to frame (19) with the bolt (20), flat ure 12-26 for motor disassembly.
washer (21), lock washer (22) and nut (23).
10-5.DRIVE MOTORS.
3. Attach frame (19) to base molding (16) by engag-
ing slots at bottom of frame (19) behind flanges NOTE: Removal procedures are covered in SEC-
near lower edge of base molding (16). TION 6.
4. Snap slots at top of front molding (15) into flanges Refer to Figure 12-27 for motor disassembly.
of base (16). Coil (8) should now be securely
attached to base (16). 10-6.BATTERIES.
5. Install spacer (14) on molding (15) and install front
NOTE: Batteries are heavy. Use care when lifting out
contact (13) with washer (10), lock washer (11)
of battery compartment.
and nut (12).
6. Place contactor on work surface with base mold- 1. Turn off the key switch and disconnect the battery
ing (16) down. Place spring (4) on center of pole connector.
piece (7). 2. Disconnect the battery cables from the battery ter-
7. Position armature plate (6) against frame (19). minals.
8. Place moving contact assembly (5) on armature 3. Lift the battery out of the battery compartment.
plate (6). Then attach braid assembly (24) to con- 4. Lower the new battery in the battery compart-
tact stud. ment.
9. Place retainer (25) over contact stud and slip the 5. Reconnect the battery cables to the battery termi-
two tabs on retainer (25) into the two slots in nals.
armature plate (6). Secure with hex nut (26).
6. Reconnect the battery connector.
10. Place two parts of rear molding (28) together and
slide back contact (2) into slot in molding. 10-7.HIGH SPEED LIMIT SWITCH.
11. Squeeze back molding (28) together and place
grooves in back molding on frame (19). Push 10-7.1.Operational Check
molding all the way down. Perform this operational check to be sure that the high
12. Release back molding (28) and press contact (2) speed limit switch is operating properly:
down into position. Armature (6) will need to be 1. Position the lift carriage so that it is higher then 24
pressed down to position contact (2). inches above the floor.
13. Reattach bus bar (1) to contact (2) with bolt (27), 2. Drive at a moderate speed and then twist the
washer (29), lock washer (30) and nut (31). directional switch to full speed. The rate of travel
14. Secure moving contact (5) to armature (6) with should not increase to top speed.
spring (4) and spring stud (3). 3. Stop and lower the lift carriage so that it is less
then 24 inches above the floor.
10-4.PUMP MOTORS.
4. Drive at a moderate speed and then twist the
Two different pump motor assemblies have been used directional switch to full speed. The rate of travel
on the SSCM Truck. Pump motor 905046 is used on should increase to top speed.
trucks serial number 334774 to 342086. Pump

10-10 900980
10-7.2.Adjustment 10-7.3.Replacement
The high speed limit switch is properly adjusted and 1. Remove two nuts and two screws securing the
inspected before it leaves the factory, so it rarely switch to the lift carriage.
needs adjustment. If operational check indicates that 2. Label and disconnect the wires from the defective
adjustment is required, proceed as follows: switch.
1. Lower lift carriage as far as it will go. 3. Connect the wires to the new switch.
2. Check that roller of switch (33, Figure 10-4) is 4. Mount the switch to the lift carriage with the two
contacting the bar welded on the inner mast face. screws and nuts.
Also check that this contact is sufficient to close
5. Check for proper operation before returning to
the switch contacts by manually depressing the
service.
roller arm (if a click is heard, the roller arm
requires adjustment). When roller arm is manually
10-8.BATTERY CHARGERS.
moved towards switch body, there should be at
least 1/16 inch clearance between roller and bar Five different chargers have been used on the SSCM
on inner mast face. Truck. Refer to the following chart to determine the
proper charger.
NOTE: Roller arm is spring loaded and will require
exertion of some pressure to check this clear- TYPE VOLTAGE PART SERIAL
ance. NO. NUMBER
Timer 120 004957-01* 334774 to
3. If roller arm does not contact bar on inner mast
Charger 334373
face or if switches clicks when roller is manually
moved toward the switch body, loosen switch Timer 240, 50 Hz 004957-02 334774 to
mounting nut, adjust the switch, and tighten nut. Charger 334373
Timer 240, 60 Hz 004957-03 334774 to
4. If switch roller cannot be manually moved to clear
Charger 334373
the bar on the inner face, loosen switch mounting
nut, adjust the switch, and tighten nut. Auto 120 004978 344374 to
Charger 374092
5. Repeat step 2. to check adjustment.
Auto 240 004980 344374 to
6. Raise the lift carriage so that the switch roller trav- Charger 374092
els above the end of the bar on the inner mast
face. * Smart Charger 004977-01 can be used to replace
the Timer Charger 004957-01. However the charger
7. Check that switch roller is not touching the inner
must be disassembled, mounting holes must be
mast face. Also check that switch contacts are
drilled for the transformer control card, and compo-
opening by depressing and releasing roller arm (a
nents of the charger mounted on various panels as
click should be heard when depressing and
shown in Figure 12-37.
releasing roller arm).
Parts identification information is shown in Figure 12-
8. If roller arm touches inner mast face, loosen lock-
32, Figure 12-33, Figure 12-34, and Figure 12-35.
nut on roller arm, adjust roller arm toward switch
body, and tighten locknut.
9. If switch does not audibly click when roller is man-
ually depressed and released, replace switch.
10. Repeat step 2. to check adjustment.

900980 10-11
10-9.EPD CONTACTOR ASSEMBLY. 10-9.2.EPD Contactor Assembly - (Assembly/Dis-
assembly)
FOR TRUCKS SERIAL NUMBER 334774 TO 1. Refer to Figure 10-9 for illustration of components
356020 SEE SUPPLEMENT 326 FOR EPD of the EPD contactor assembly, and remove
CONTACTOR RETROFIT KIT 31366 defective components as required.
2. Upon reassembly of the EPD contactor assembly,
inspect each electrical connection to ensure that a
10-9.1.Assembly Replacement (Trucks serial num- good positive contact is made at all wire and
ber 356021 to 374092). cable connections.
1. Turn off the key switch and disconnect the battery.
10-10.EPD Contactor Repair
2. Remove the lower access door (16, Figure 12-8).
3. Tag and disconnect all electrical wires and cables 1. Refer to Figure 10-10 for illustration of compo-
from the EPD contactor assembly. nents included in the contactor repair kit, part
number 906000.
4. Remove the two nuts (3, Figure 10-6), two lock-
washers (4), two flat washers(5) and spacer (6). 2. Remove washer (1), spring (2), bridge assembly
and remove the EPD assembly (3), bushing (4) and bussbar assemblies (5).

5. Install the EPD contactor assembly in reverse 3. Install new parts by reversing the procedure.
order.

USED ON TRUCKS
SERIAL NUMBERS
356021 TO 374092

R6044

Figure 10-9 EPD Contactor Assembly

10-12 900980
 R6045

Figure 10-10 400 Amp Contactor Service Kit

900980 10-13
 NOTES

10-14 900980
 SECTION 11
OPPTIONAL EQUIPMENT

11-1.HOUR METER
The hour meter is attached to the motor circuits to indi-
cate actual usage of the drive and lift function. Refer to
Figure 12-37 for replacement parts and to the wiring
diagram, Figure 4-10 or Figure 4-11 for wiring informa-
tion.

11-2.BATTERY CAPACITY INDICATOR.

Refer to Figure 12-38 or Figure 12-39 for the battery
capacity indicator replacement parts.

11-3.LIFT LIMIT AND LIFT LIMIT OVERRIDE.

The lift limit switch is attached to a bracket on the lift
carriage. The LIFT LIMIT OVERRIDE switch is located
on the right side of the Control Console. Refer to Fig-
ure 12-36 as a guide in disassembly and parts identifi-
cation.

11-4.FLASHING RED LIGHT.

The optional flashing red light is mounted on top of the
electrical compartment. Refer to Figure 12-40 as a
guide in disassembly and to identify replacement
parts. Refer to Figure 12-41 for wiring information.

11-5.SIDE GUIDE ROLLERS.

The side guide rollers are an optional accessory. To
R5756
repair the rollers proceed as follows:
1. Remove retaining ring (4, Figure 11-1). Figure 11-1 Operator Safety Belt
2. Remove roller (3) with bearing (2) from spindle
(1). 11-7.SLIP ON PLATFORM.

3. Remove snap ring (5) and press bearing (2) out of The slip on platform is attached to the lift carriage. The
roller (3). arrangement of safety chains must be as shown in
Figure 12-46.
4. To install, reverse the removal
11-8.BATTERY QUICK DISCONNECT CABLES
11-6.OPERATOR SAFETY HARNESS AND BELTS.
The battery quick disconnect cables allows fast battery
The operator safety harness (Figure 12-43) has shoul- exchange in a lift truck. Refer to Figure 12-47 for
der straps that are adjustable to fit the individual oper- replacement parts.
ator. In use the safety lanyard is attached to the
special 1/2-inch diameter rod on the overhead guards
the other end is attached to the ring on the safety har-
ness. The Safety belt and lanyard (Figure 12-44) also
is attached to the rod on the overhead guard. The
Safety belt (Figure 12-45) is attached to two eyebolts
on the lift carriage by two 8-inch chains.

900980 11-1
 NOTES

11-2 900980
 SECTION 12
ILLUSTRATED PARTS BREAKDOWN

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

900980 12-1
 CABLE KIT
PART NUMBER
900514
CONTAINS:
ITEM QTY
20 31
21 2
26 2

R3121

Figure 12-1 Steering Controls (Sheet 1 of 3)

12-2 900980
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R3122

Figure 12-1 Steering Controls (Sheet 2 of 3)

900980 12-3
 USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374092

R5881

Figure 12-1 Steering Controls (Sheet 3 of 3)

12-4 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 402729 SHAFT 1 24 061010 PIN-ROLL, 1/4 X 1-3/4 1
2 057901 KEY-WOODRUFF, #606, 1 25 052952 BEARING-FLANGED 1
3/16 X 3/4 26 053317* RE-USABLE STUD SOCKET 2
3 052951 BEARING 1 ASSY W/JAM NUT
4 077084 WASHER- 49/64 x 1-3/4 x 1/4 2 27 059530** NUT-HEX, JAM, 3/8-24 6
5 051154 BEARING-THRUST 2 27 059530*** NUT-HEX, JAM, 3/8-24 2
6 052950 BEARING-THRUST 1 28 076213 TURNBUCKLE 2
7 073474 SCREW-SET, 1/4-20 X 1/4”LG 3 29 059431 HEX NUT, 3/8-24, LEFT HAND 2
THD
8 800047 SPROCEKT 1
30 053309*** LOWER STEERING CABLE 2
9 077061 WASHER- 3/4 X 1-3/4 X 14 GA 1
ASSY 130” LIFT HT
10 061719 RING-SNAP, EXT., 3/4” DIA 2
(TELESCOPIC)
11 800045 GEAR-IDLER 1
30 053319*** LOWER STEERING CABLE 2
12 077209 WASHER-LOCK, SPLIT, 1/4 4 ASSY 67” LIFT HT (NON-TEL)
13 065476 SCREW-HEX HD, 1/4-20 X 1/2” 4 30 904800** LOWER STEERING KIT 1
14 402694 COVER CONSOLE 1 67” & 130” LIFT HTS.
15 079403 STEERING WHEEL AND 1 31 077064 WASHER-0.641 X 1.062 X 7 GA 8
BUSHING 32 074260 SHEAVE-IDLER, RAMHEAD 8
16 059547 NUT-HEX, JAM, 3/4-16 1 33 063813 SCREW-HEX HEAD 5/8-11 X 2-1/4 8
17 800046 IDLER SPROCKET GEAR 1 34 059544 HEX-NUT, JAM, 5/8-11 8
18 055625 ROLLER CHAIN 1 35 077215 WASHER-LOCK, SPLIT, 5/8 8
19 058351 LINK-CONNECTING, 5/8P 2 36 059529** NUT, HEX, JAM, 3/8-16 2
20 053307* CABLE-3/16”, 7 X 19 31 FT 37 064607** SCREW-HEX HEAD, 1
GALVANIZED 3/8-16 X 1-1/4
21 053316* RE-USABLE EYE SOCKET ASSY 2 38 063603** SCREW-HEX HEAD, 1
FOR STEERING 3/8-16 X 3/4
22 052953 BEARING 1 39 074809 SPINNER-WHEEL, STEERING 1
23 800282 PINION-STEERING 1 40 077010 WASHER-0.765 X 1.500 X 14 GA 1
* CONTAINED IN UPPER STEERING CABLE KIT, PART NUM-
BER 900514, USED ON TRUCKS SERIAL NUMBER 334774
TO 354286.
** USED ON TRUCKS SERIAL NUMBER 354287 TO 374092.
*** USED ON TRUCKS SERIAL NUMBER 334774 TO 354287

900980 12-5
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R3123

Figure 12-2 Steering Sheave and Pivot Bushing

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 065603 SCREW-SOC HD, 3/8-16 X 3/4 2 10 800005 PIN-SUPPORT, SPRING 2
2 402719 CAP-PIVOT 1 11 051146 BEARING-BALL, THRUST, PIVOT 1
TUBE
3 061000 PIN-ROLL, 1/4 DIA X 5/8 LG 1
12 401695 RING-SUPPORT 1
4 064607 SCREW-HEX HEAD 4
13 053108 BEARIBNG-FLANGE, PIVOT, 1
5 077211 WASHER-LOCK, SPLIT, 3/8 8
UPPER
6 800075 SHEAVE-STEERING 1
14 060417 PIN-COTTER 2
7 504968 TUBE WELDM’T-PIVOT 1
15 283902 SUPPORT-SPRING 2
8 053107 BEARING-FLANGE, PIVOT, 1
LOWER
9 065538 SCREW-SOC BUT. HD, 3
5/16-18 X 5/8

12-6 900980
 USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374092

4
5

R5882

Figure 12-3 Steering Sheave and Pivot Bushing

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 065603 SCREW-SOC HD, 3/8-16 X 3/4 2 9 065538 SCREW, SOC BUT HD, 3
5/16-18 X 5/8
2 402719 CAP-PIVOT 1
10 800005 PIN-SUPPORT, SPRING 2
3 061002 PIN-ROLL, 1/4 DIA X 3/4 LG 1
11 051146 BEARING-BALL, THRUST, PIVOT 1
4 064717 SCREW-HEX HEAD 4
TUBE
5 077213 WASHER-LOCK, SPLIT, 1/2 4
12 401695 RING-SUPPORT 1
6 403660 SHEAVE-STEERING 1
13 053108 FLANGE BUSHING, UPPER 1
7 505684-01 PIVOT TUBE 1
PIVOT
8 053107 BUSHING-FLANGE, PIVOT, 1
14 060417 PIN-COTTER, 3/32 DIA X 3/4 LG 2
LOWER
15 283902 SUPPORT-SPRING 2

900980 12-7
 R5749

Figure 12-4 Carriage Brake Components

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 051677 RESERVOIR-BRAKE 1 10 — NOT USED
2 026149 NIPPLE-1/8NPT X 1.0 LG, BRASS 1 11 038171-01 HOSE-BRAKE, NON-TEL 1
(67” LIFT)
3 051676* ACTUATOR-BRAKE (COMPLETE 1
WITH HARDWARE) 11 038171-03 HOSE-BRAKE, TEL 1
(130” LIFT)
4 026715 ELBOW, MALE 1
12 402974 CLAMP 4
5 505227 PEDAL-BRAKE 1
13 077209 WASHER-LOCK, SPLIT, 1/4 4
6 060940 PIN-ROLL, 1/8 DIA X 1 LG 1
14 059421 NUT-HEX, 1/4-20 4
7 060217 PIN-CLEVIS, 1/4 DIA X 1.25 LG 1
15 063483 SCREW-HEX HD, 1/4-20 X 1-3/4 4
8 402730 SHAFT 1
16 403338 PAD - BRAKE PEDAL 1
9 060417 PIN-COTTER, 3/32 DIA X 3/4 LG 1

* REPAIR KIT PART NUMBER 901176.

12-8 900980
 NOTES

900980 12-9
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 354286

R5757

Figure 12-5 Chassis Brake Components

12-10 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — MOTOR, DRIVE, 247V REF 32 064605 SCREW-HEX HD, 3/8-16 X 1 2
(FIGURE 12-27) 33 077211 WASHER-LOCK, SPLIT, 3/8 5
2 059645 NUT-LOCK, 5/8-18, FLEX 1 34 077215 WASHER-LOCK, SPLIT, 5/8 1
3 505211 DISC ASSY 1 35 052821 BRAKE ASSY-DISC, 5 1
4 057901 KEY-WOODRUFF, #606, 1 36 059421 NUT-HEX, 1/4-20 2
3/16 X 3/4 37 077209 WASHER-LOCK, SPLIT, 1/4 2
5 063560 SCREW-HEX HD, 5/16-18 X 1-3/4 4 38 901195 BRACKET 1
6 077210 WASHER-LOCK, SPLIT, 5/16 4 39 901190 SPACER 2
7 505209 BRACKET ASSY 1 40 901191 SPRING 2
8 059529 NUT-HEX, JAM, 3/8-16 1 41 901188 PAD 1
9 060417 PIN-COTTER, 3/32 DIA X 3/4 LG 4 42 901189 BOLT 2
10 402743 ROD 1 43 901198 E-RING 1
11 075091 SPRING, EXTERSION, BRAKE 1 44 901197 WASHER 1
12 505213 BLOCK 1 45 901196 SPRING 1
13 060216 PIN-CLEVIS, 1/4 1 46 901194 LEVER 1
14 026715 ELBOW-MALE 1 47 901193 WASHER 1
15 051675* CYLINDER-SLAVE, BRAKE 1 48 901192 BRAKE PAD WITH PIN 1
16 403146 BARREL-BRAKE 1 49 — PIVOT TUBE (FIGURE 12-2) 1
17 060212 PIN-CLEVIS, 5/16 X 1.12 LG 1 50 069716 SCREW-SOC FL HD, 4
18 505216 CLEVIS WELDM’T 1 1/2-13 X 1-1/4
19 060435 PIN-COTTER, 5/32 DIA X 1 LG 1 51 — SCREW-HEX HEAD REF
20 505217 BRAKE LEVER 1 (FIGURE 12-7)
21 053106 BUSHING-FLG, NYLON, 5/16 DIA 1 52 — WASHER-LOCK, SPLIT, 5/8 REF
(FIGURE 12-7)
22 402982 BOLT-SHOULDER 1
23 258128 PIVOT PIN 1
53 — DRIVE WHEEL ASSEMBLY REF
(FIGURE 12-7)
24 505212 BRACKET WELDMENT 1
54 — . TIRE (FIGURE 12-7) REF
25 021718 TERMINAL-SLIP ON, 1/4” INSUL 2
55 — . HUB (FIGURE 12-7) REF
26 023018 WIRE-16 GA, BLACK A/R
56 — TRANSMISSION (FIGURE 12-7) REF
27 021210 TERMINAL-FORK, INSUL, #6, 2
14-16 GA
57 — SCREW-HEX HD (FIGURE 12-2) REF

28 020729 SWITCH-DEADMAN 1
58 — WASHER-LOCK, SPLIT REF
(FIGURE 12-2)
29 009602 HORN-24V W/BRACKET 1
59 — SHEAVE-STEERING REF
30 504116 SUPPRESSOR ASSY-SPIKE 1
(FIGURE 12-2)
31 064605 SCREW-HEX HD, 3/8-16 X 1 2

A/R - AS REQUIRED
* REPAIR KIT PART NUMBER 901175.

900980 12-11
 USED ON TRUCKS
SERIAL NUMBERS
354287 TO 374092

R5879

Figure 12-6 Chassis Brake Components

12-12 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — MOTOR, DRIVE, 247V REF 33 077211 WASHER-LOCK, SPLIT, 3/8 5
(FIGURE 12-27) 34 077215 WASHER-LOCK, SPLIT, 5/8 1
2 059645 NUT-LOCK, 5/8-18, FLEX 1 35 052821 BRAKE ASSY-DISC, 5 1
3 505211 DISC ASSY 1 36 059421 NUT-HEX, 1/4-20 2
4 057901 KEY-WOODRUFF, #606, 1 37 077209 WASHER-LOCK, SPLIT, 1/4 2
3/16 X 3/4 38 901195 BRACKET 1
5 063560 SCREW-HEX HD, 5/16-18 X 1-3/4 4 39 901190 SPACER 2
6 077210 WASHER-LOCK, SPLIT, 5/16 4 40 901191 SPRING 2
7 505209 BRACKET ASSY 1 41 901188 PAD 1
8 059529 NUT-HEX, JAM, 3/8-16 1 42 901189 BOLT 2
9 060417 PIN-COTTER, 3/32 DIA X 3/4 LG 4 43 901198 E-RING 1
10 402743 ROD 1 44 901197 WASHER 1
11 075091 SPRING, EXTERSION, BRAKE 1 45 901196 SPRING 1
12 505213 BLOCK 1 46 901194 LEVER 1
13 060216 PIN-CLEVIS, 1/4 1 47 901193 WASHER 1
14 026715 ELBOW-MALE 1 48 901192 BRAKE PAD WITH PIN 1
15 051675* CYLINDER-SLAVE, BRAKE 1 49 — PIVOT TUBE (FIGURE 12-3) 1
16 403146 BARREL-BRAKE 1 50 069716 SCREW-SOC FL HD, 4
17 060212 PIN-CLEVIS, 5/16 X 1.12 LG 1 1/2-13 X 1-1/4
18 505216 CLEVIS WELDM’T 1 51 — SCREW-HEX HEAD REF
19 060435 PIN-COTTER, 5/32 DIA X 1 LG 1 (FIGURE 12-7)
20 505217 BRAKE LEVER 1 52 — LOCK WASHER, SPLIT, 5/8 REF
(FIGURE 12-7)
21 053106 BUSHING-FLG, NYLON, 5/16 DIA 1
22 402982 BOLT-SHOULDER 1
53 — DRIVE WHEEL ASSEMBLY REF
(FIGURE 12-7)
23 258128 PIVOT PIN 1
54 — . TIRE (FIGURE 12-7) REF
24 505212 BRACKET WELDMENT 1
55 — . HUB (FIGURE 12-7) REF
25 021718 TERMINAL-SLIP ON, 1/4” INSUL 2
56 — TRANSMISSION (FIGURE 12-7) REF
26 023018 WIRE-16 GA, BLACK A/R
57 — SCREW-HEX HD (FIGURE 12-3)
27 021210 TERMINAL-FORK, INSUL, #6, 2
14-16 GA
58 — WASHER-LOCK.SPLIT
(FIGURE 12-3)
28 020729 SWITCH-DEADMAN 1
59 074328-01 SHIM, 0.010, BROWN A/R
29 800083 HORN-24V W/BRACKET 1
59 074328-02 SHIM, 0.015, PINK A/R
30 504096 SUPPRESSOR ASSY, SPIKE 1
59 074328-03 SHIM, 0.030, CORAL A/R
31 064605 SCREW-HEX HD, 3/8-16 X 1 2
32 064605 SCREW-HEX HD, 3/8-16 X 1 2
A/R - AS REQUIRED
* REPAIR KIT PART NUMBER 901175.

900980 12-13
 R3164

Figure 12-7 Transmission

12-14 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505041 TRANSMISSION ASSY 1 22 063552 . SCREW-HEX HD, 4
5/16-18 X 5/8
1 050700 . SHAFT-AXLE, WHEEL, DRIVE 1
23 077210 . WASHER-LOCK, SPLIT, 5/16 4
2 073504 . SEAL-OIL, 2.875 X 3.756 1
24 064620 . SCREW-HEX HD, 2
3 051112 . CONE-BEARING, 1.652 ID 2
3/8-16 X 3-3/4
4 051111 . CUP-BEARING, 3.000 OD 2
25 064615 . SCREW-HEX HD, 2
5 026302 . PLUG-SQ HD, MAGN., 3/8 NPT 1
3/8-16 X 2-1/4
6 057210 . GEAR-SPUR, 58 TEETH 1
26 060428 . PIN-COTTER, 1/8 DIA X 1-1/4 LG 1
7 077600 . WASHER-LOCK, (TW65) 1
27 059745 . NUT-HEX, SLOTTED, 5/8-18 1
8 059680 . NUT-LOCK, (TN65), 1.312-18 1
28 057234 . SPUR-PINION, 17 TEETH 1
9 051126 . BEARING-BALL, (3205), NO 1
29 — . NOT USED
SELAS
30 060585 . PIN-DOWEL, 3/8 DIA X 1-1/4 LG 3
10 057902 . KET, 5/16 X 5/16 X 1-3/8 1
31 800278 . HOUSING-TRANSMISSION 1
11 057211 . GEAR-PINION 17 TEETH 1
32 026304 . SQUARE PLUG (ORDER 1
12 057233 . GEAR-SPUR, 111 TEETH 1
026310)
13 074701 . SPACER-PINION, SPUR 1
— 500935 WHEEL ASSY-DRIVE, POLY, 1
14 051125 . BEARING-BALL, (3204), NO 1 10-1/2
SEALS
33 800035 . HUB-WHEEL, MACHINED 1
15 074706 . SPACER-CAP, BEARING 1
34 079160 WHEEL-DRIVE, POLY, 10-1/2 1
16 036105 . GASKET-COVER, XMSN 1
35 077215 . WASHER-LOCK, SPLIT, 5/8 5
17 800073 . COVER-TRANSMISSION 1
36 064828 . SCREW-HEX HD, 5/8-18 X 1-1/8 5
18 077211 . WASHER-LOCK,SPLIT, 3/8 11
37 042114 O-RING - 2.859ID X 3.167OD 1
19 064611 . SCREW-HEX HD, 7
38 — DRVIE MOTOR (FIGURE 12-27) REF
3/8-16 X 1-3/4
39 026704 STREET ELBOW, 3/8 NPT, 90° 1
20 036106 . GASKET-CAP BRG 1
40 076701 VENT, 3/8NPT 1
21 051159 . CAP-BEARING 1

900980 12-15
 R3127

Figure 12-8 Base and Frame

12-16 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 071376 SCREW-PH TR HD, 10-32 X 1/2 8 11 505093 SPACER (USED WITH 220 AMP 2
BATTERY)
2 055500 CATCH-FASTENER, DOOR 1
11 501476 SPACER (USED WITH 300 & 340 2
3 503014 DOOR WELDMT-CABINET 1
AMP BATTERY)
4 070477 SCREW-PH RD HD, 1/4-20 X 5/8 3
12 070476 SCREW- PH RD HD, 1/4-20 X 1/2 2
5 003149 BATTERY-12 V, 200 AMP DRY 2
13 VAR MAIN FRAME 1
6 402707 SPACER-HINGE 1
14 058100 LATCH-DOOR 1
7 505043 COVER WELDMENT 1
15 059416 NUT- HEX, 10-32 4
8 402458 PAD 1
16 402986 DOOR-ACCESS 1
9 077208 WASHER-LOCK, SPLIT, #12 8
17 069478 SCREW-PH FL HD, 1/4-20 X 3/4 4
10 003152 BATTERY-INDSTRL, 24V, 1
18 059421 NUT-HEX, 1/4-20 3
220 AMP (WET)
19 077209 WASHER-LOCK, SPLIT, 1/4 3
10 003139 BATTERY-INDSTRL, 24V, 1
300 AMP (WET) 20 077031 WASHER, 5/16 X 3/4 X 16 GA 3
10 003140 BATTERY-INDSTRL, 24V, 1 — 901201 PAINT-AEROSOL CAN, A/R
340 AMP (WET) BJ YELLOW
— 901202 PAINT-AEROSOL CAN, A/R
BJ BLACK SATIN
A/R - AS REQUIRED

900980 12-17
 R5617

Figure 12-9 Decal Location

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 901042 SSCM DECAL KIT 1 10 056622 . DECAL-ARROW 1
1 056588 . DECAL-SSC/SSCM SAFETY 1 11 056631 . DECAL-DOOR, BIG JOE 1
MYLAR 12 056644 . DECAL-TO DRIVE/TO CHARGE 1
2 056621 . DECAL-E.P.D., SSCM 1 13 056654 . DECAL-NOTICE, EPD 1
3 056595 . NAMEPLATE-LOGO, DECOR 1 14 056646 . DECAL-CAUTION, BATTERY 1
4 056596-11 . DECAL-SSCM 1 15 056632 . DECAL-MAST, BIG JOE 2
5 800281 . DECAL-SPEED CONTROL 1 16 20574* . DECAL-PUSH TO ENERGIZE 1
6 056564 . DECAl-CAUTION, ACCESS 4 17 056648 . DECAL-INSTRUCTIONS, 1
PANEL CHARGER
7 056630 . DECAL-DOWN 1 18 056620 . DECAL-WARNING, PINCH 2
8 056626 . DECAL-OIL LEVEL 1
9 056629 . DECAL-LOWERING, 1
EMERGENCY, SSC
* USED ON TRUCKS SERIAL NUMBER 356021 TO 374092.

12-18 900980
 R3126

Figure 12-10 Load Wheel

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 061725 RING-SNAP, EXT., 1 DIA 2 5 078618* WHEEL ASSY, 6” DIA POLY 2
(4” WIDE HOUSING)
2 050703 AXLE-WHEEL, LOAD, 0.984 X 4 2
(SSCM 20-130 OPTIONAL)
2 050710 AXLE-WHEEL, LOAD, 0.984 X 3 2
5 504276** WHEEL ASSY, 6” DIA POLY 2
3 060976 PIN-ROLL, 3/16 DIA X 1-1/2 LG 4 (3” WIDE HOUSING)
4 077033 WASHER, 1.015 X 2.50 X 14 GA 4 (SSCM 20-67 STANDARD)
5 078414* WHEEL ASSY, 4” DIA POLY 2 5 078237* WHEEL ASSY, 3” DIA POLY 2
(4” WIDE HOUSING) (4” WIDE HOUSING)
(SSCM 20-130 STANDARD) (SSCM 20-67 OPTIONAL)
5 501165** WHEEL ASSY, 4” DIA POLY 2 6 051136 . BEARING-BALL, (3205), 2 SEALS 2
(3” WIDE HOUSING)
(SSCM 20-130 OPTIONAL)
* USED WITH AXLE PART NUMBER 050703.
** USED WITH AXLE PART NUMBER 050710.

900980 12-19
 R5750

Figure 12-11 Elevation System (SSCM 20-67)

12-20 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 077209 WASHER-LOCK, SPLIT 1/4 2 20 059545 NUT-HEX, JAM, 5/8-18 2
2 063478 SCREW-HEX HD, 1/4-20 X 3/4 2 21 077215 WASHER-LOCK, SPLIT, 5/8 2
3 025712 FITTING-GREASE, 3/16 DRIVE 4 22 059445 NUT-HEX, 5/8-18 2
4 800287 BOLT, SHOULDER, 3/8-16 2 23 236001 SPINDLE-MAST 4
5 504956 SHEAVE & BEARING ASSY 1 24 053012 WASHER-THRUST, 3/32 THK A/R
6 402670-01 TUBE-SPACER 2 24 053013 WASHER-THRUST, 1/8 THK A/R
7 074260 SHEAVE-IDLER, RAMHEAD 2 24 053014 WASHER-THRUST, 5/32 THK A/R
8 051120 BEARING-ROLLER, 2 24 053015 WASHER,-THRUST, 3/16 THK A/R
1.125 X 1.50 X 1.25 25 500166 ROLLER ASSY-STRAIGHT, 3 DIA 4
9 074251 SHEAVE-HD 2 26 051145 . BEARING-NEEDLE, 4
10 800294 RAMHEAD 1 1.255 X 1.75 X 1
11 064711 SCREW-HEX HD, 1/2-13 X 1 3/4 1 27 243401 . ROLLER-MAST 4
12 077213 WASHER-LOCK, SPLIT, 1/2 1 28 064605 SCREW-HEX HD 3/8-16 X 1 1
13 505057 SHEAVE ASSY 1 29 077076 WASHER, 13-32 X 1-/2 X 7 GA 1
14 059429 NUT-HEX, 3/8-16 2 30 — CYLINDER ASSEMBLY REF
(FIGURE 12-16)
15 077211 WASHER-LOCK, SPLIT, 3/8 3
31 402034 CHAIN-LIFT, BL534 (58” EACH) 2
16 101072 CLAMP-CYL 1
32 403576 TUBE-SPACER 2
17 060402 PIN-COTTER, 1/16 DIA X 3/8 LG 4
33 077056 WASHER, 7/16 X 1 X 14 GA 2
18 402055 PIN-CHAIN, 0.234 DIA 4
34 061728 RING-SNAP, EXT., HD, 1-1/8” DIA 2
19 402051 BOLT-CHAIN ADJUSTING 2

900980 12-21
 R5751

Figure 12-12 Elevation System (SSCM 20-130)

12-22 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 077211 WASHER-LOCK, SPLIT, 1/4 2 22 059445 NUT-HEX, 5/8-18 2
2 063603 SCREW-HEX HD, 1/4-20 X 3/4 2 23 236001 SPINDLE-MAST 4
3 025712 FITTING-GREASE, 3/16 DRIVE 6 24 053012 WASHER-THRUST, 3/32 THK A/R
4 800287 BOLT-SHOULDER, 3/8-16 2 24 053013 WASHER-THRUST, 1/8 THK A/R
5 504956 SHEAVE & BEARING ASSY 5 24 053014 WASHER-THRUST, 5/32 THK A/R
6 402670-01 TUBE-SPACER 2 24 053015 WASHER-THRUST, 3/16 THK A/R
7 074260 SHEAVE-IDLER, RAMHEAD 2 25 500167 ROLLER ASSY-TAPERED, 3DIA 6
8 051120 BEARING-ROLLER, 2 26 051145 . BEARING-NEEDLE, 6
1.125 X 1.50 X 1.25 1.25 X 1.75 X 1
9 074251 SHEAVE-HD 2 27 401046 . ROLLER-MAST 6
10 800294 RAMHEAD 1 28 064605 SCREW-HEX HD, 3/8-16 X 1 1
11 064711 SCREW-HEX HD, 1/2-13 X 1-3/4 1 29 077076 WASHER, 13-2 X 1-1/2 X 7 GA 1
12 077213 WASHER-LOCK, SPLIT, 1/2 1 30 — CYLINDER ASSEMBLY REF
(FIGURE 12-16)
13 505057 SHEAVE ASSY 1
31 402034 CHAIN LIFT, BL534 (112” EACH) 2
14 059429 NUT-HEX, 3/8-16 2
32 500166 ROLLER ASSY-STRAIGHT, 3 DIA 2
15 077211 WASHER-LOCK, SPLIT 3/8 3
33 243401 . ROLLER-MAST 2
16 101072 CLAMP-CYL 1
34 051145 . BEARING-NEEDLE, 2
17 060402 PIN-COTTER, 1/16 DIA X 3 LG 4
1.25 X 1.75 X 1
18 402055 PIN-CHAIN, 0.234 DIA 4
35 504954-01 INNERMAST WELDM’T-SSCM 1
19 402051 BOLT-CHAIN, ADJUSTING 2
36 403576 TUBE-SPACER 2
20 059545 NUT-HEX, JAM, 5/8-18 2
37 077056 WASHER, 7/16 X 1 X 14 GA 2
21 077215 WASHER-LOCK, SPLIT, 5/8 2
38 061728 RING-SNAP, EXT, HD, 1-1/8” DIA 2

900980 12-23
 R5752

Figure 12-13 Lift Carriage

12-24 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 VAR LIFT CARRIAGE 1 5 070478 SCREW-PH, RD HD, 1/4-20 X 3/4 4
2 VAR PANEL-CARRIAGE ACCESS 1 6 065476 SCREW-HEX HD, 1/4-20 X 1/2 4
3 079520 PLEXIGLASS WINDOW, ASSY 1 7 403760 MAT-FLOOR, SAFETY 1
4 077209 WASHER-LOCK, SPLIT, 1/4 8

900980 12-25
 R5753

Figure 12-14 Hydraulic System

12-26 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 070476 SCREW-PH RD HD, 1/4-20 X 1/2 3 29 063602 SCREW-HEX HD, 3/8-16 X 5/8 2
2 505859 BREATHER CAP & DIPSTICK 1 30 402742 PLATE-MOUNTING 1
ASSY 31 048133 VALVE-SOLENOID, LOWERING, 1
3 026506 REDUCER-PIPE, 3/4-3/8 1 24V
4 503390* HYDRAULIC RESERVOIR 1 32 056105 CABLE CLAMP 2
4 505931** HYDRAULIC RESERVOIR 1 33 318200 HOSE-SUCTION, 3/4, A/R
NEOPRENE, 18.5 INCHES
5 025501 ELBOW, 90°, 1/4 NPT X TUBE 2
6 282500 TUBING-VINYL, A/R 34 800144 COUPLING-MACHINED 1
1/4 OD - 0.180 ID, 10 FT 35 026143 NIPPLE, 3/8NPT X CLOSE 1
7 042130* O-RING 1 36 025505 ELBOW, 90°, 3/8 NPT 1
8 026128 NIPPLE-HOSE, 3/8 NPT - .675 DIA 2 37 026711 STREET-ELBOW, 3/8 X 45 2
9 056110 CLAMP-HOSE, SCREW TYPE, 2 38 025107 CONNECTOR-SWVL, 3/8 NPT 1
0.50/1.91 39 048168 RELIEF VALVE 1
10 308900 HOSE-L.P. RUBBLE, A/R 40 025338 REDUCER CONNECTOR, 1
0.62 ID X 90 OD 3/8 X 1/4
11 505001 COVER WELDM’T, HYDRAULIC 1 41 071376 SCREW-PH TR HD, #10-32 X 1/2 2
12 025543 ELBOW-MALE, 45°, 2 42 077208 WASHER-LOCK, SPLIT, #12 2
3/8 NPT X 3/8 JIC 43 505000 VALVE WELDMENT-RELEASE 1
13 048124 VALVE-RELIEF, PILOTP 1 44 026708 ELBOW-STREET, 90°, 1/4 NPT 1
14 — CYLINDER ASSEMBLY REF 45 025524 ELBOW, 90°, 1/4 JIC 1
(FIGURE 12-16)
46 065538 SCREW-SOC BUT HD, 1
15 026707 ELBOW-STREET, 90°, 3/8 NPT 2 5/16-18 X 5/8
16 026116 NIPPLE-PIPE, 3/8 NPT HD X 3 LG 1 47 077210 WASHER-LOCK, SPLIT, 5/16 2
17 047110 VALVE-FLOW REG, 3.5 GPM 1 48 077011 WASHER, 3/8 X 7/8 X 14 GA 1
18 026109 NIPPLE-HEX, 3/8 NPT 4 49 026302 PLUG-SQ HD, MAGN, 3/8 NPT 1
19 505077-01 HOSE ASSY, 3/8 1 50 035108* SUMP FILTER 1
20 — NOT USED 50 035114** SUMP FILTER 1
21 027118 TEE-MALE BRANCH, 1/4 NPT 1 51 400754* PLATE-HOLD DOWN 1
22 026500 REDUCER-PIPE, 3/8-1/4 2 52 059628* CENTER LOCK NUT, 5/16-18 2
23 027107 TEE-TEE 3/8 NPT 2 53 800145 NIPPLE-MACHINED 1
24 026114 NIPPLE, 3/8 NPT X CLOSE, HD 1 54 025114 ADAPTER-FEM, 1
25 025131 ADAPTER-STRT, SWVL NUT, 1 3/4 SAE X 3/8 NPT
9/16-3/8 55 — PUMP & MOTOR ASSEMBLY, 24V 1
26 504592-02 HOSE ASSY, 1/4, MALE & 2 (FIGURE 12-23, FIGURE 12-25 &
FEMALE SWVL FIGURE 12-26)
27 025524 ELBOW-90°, 1/4 JIC 1 56 059429 NUT-HEX, 3/8-16 4
28 077211 WASHER-LOCK, SPLIT, 3/8 6
* USED WITH TRUCKS SERIAL NUMBER 334774 TO 357009.
** USED WITH TRUCKS SERIAL NUMBER 357010 TO 374092.

900980 12-27
 R3165

Figure 12-15 Carriage Operated Manual Lowering Components

12-28 900980
 INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 057962 KNOB-ROUND, 3/8-16 1 22 063478 SCREW-HEX HD, 1/4-20 X 3/4 6
2 — DECAL (FIGURE 12-9) REF 23 505124 BRACKET WELDM’T-VALVE & 1
SHEAVE
3 505123 BRACKET WELDM’T-LEVER, 1
LOWER 24 402864 ROD-ADJUSTMENT, LOWER 1
4 505122 LEVER WELDM’T-VALVE 1 25 075065 SPRING-THROTTLE VALVE 1
5 065476 SCREW-HEX HD, 1/4-20 X 1/2 2 26 402977 WASHER-SPRING 1
6 077209 WASHER-LOCK, SPLIT, 1/4 8 27 059529 NUT-HEX, JAM, 3/8-16 2
7 073461 SCREW, SET, #10-24 X 3/8 LG 1 28 503050 VALVE ASSY-LOWERING 1
8 061709 RING-SNAP, EXT., 3/8 DIA 1 29 060403 PIN-COTTER, 1/16 DIA X 1/2 LG 1
9 077056 WASHER, 7/16 X 1 X 14 GA 1 30 077031 WASHER-FLAT, 2
5/16 X 3/4 X 16 GA
10 403030 BOLT-SHOULDER 1
31 402976 LINK-CONNECTING, VALVE 1
11 318901 SPACER 5
32 060319 PIN-CLEVIS, 1/4 X 3/4 1
12 074267 SHEAVE & BEARING ASSY 5
33 026707 ELBOW-STREET, 90°, 3/8 NPT 1
13 800267 BOLT, 3/8 1
34 026500 REDUCER-PIPE, 3/8-1/4 1
14 077211 WASHER-LOCK, SPLIT, 3/8 5
35 504314-13 HOSE ASSY-FEMALE, SWIVEL, 1
15 064605 SCREW-HEX HD, 3/8-16 X 1 1
1/4
16 — DECAL (FIGURE 12-9) REF
36 308900 HOSE, L.P., RUBBER, 56”
17 077009 WASHER, 1/2 X 3/4 S 16 GA 1
0.62 ID X 0.90 OD
18 077011 WASHER,3/8 X 7/8 X 14 GA 4
37 056112 CLAMP 1
19 064609 SCREW-HEX HD, 3/8-16 X 1-1/2 3
38 026128 NIPPLE-HOSE, 1
20 059429 NUT-HEX, 3/8-16 3 3/8 NPT - 0.675 DIA
21 053313 CABLE, 3/32 INCH 20 FT 39 025524 ELBOW, 90° X 1/4 JIC 1

900980 12-29
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 351487
ORDER RETROFIT
KIT 907122
R6107

RETROFIT KIT
907122
CONTAINS:
ITEM QTY
2 1
4 1
7 1
11 1
14 1
15 1

PACKING KIT
907121
CONTAINS:
ITEM QTY
2 1
4 1
7 1
11 1
15 1

R6106

Figure 12-16 Lift Cylinder Assembly

12-30 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 503568-13 CYL ASSY-LIFT (SSCM 20-130) 1 7 042105* . O-RING, 3/4 ID X 1 OD 1
— 503568-15 CYL ASSY-LIFT (SSCM 20-67) 1 8 —** . PISTON-RAM 1
1 — . TUBE, CYLINDER 1 9 —** . PACKING SET 1
2 049509* . RING-WIPER, 2.000 DIA ROD 1 10 077005** . WASHER, 0.760 X 2.437 X 10 GA 1
3 800024 . NUT-GLAND 1 11 800293* . NUT-GLAND, NYLOK 1
4 042113* . O-RING, 2-1/5 ID X 2-3/4 OD 1 12 061023 . PIN-ROLL, 5/16 DIA X 3/4 LG 1
5 — . ROD, CYLINDER 1 13 —** . WASHER, 0.765 X 1.250 X 20 GA 1
6 402876 . TUBING-JACKSTOP 1 14 403864 . PISTON, 2.50 DIA CYL 1
(SSCM 20-130) 15 042205-02* . PSP SEAL, 2.50 DIA CYL 1
6 400866 . TUBING-JACKSTOP 1
(SSCM 20-67)
* PACKING KIT 907121 INCLUDES 2, 4, 7, 11 AND 15.
** CYLINDERS EQUIPPED WITH PISTON, ITEM 8 ORDER
RETROFIT KIT 907122. RETROFIT KIT 907122 INCLUDES
2, 4, 7, 11, 14 AND 15.

900980 12-31
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 351122

R5661

Figure 12-17 Carriage Mounted Electrical Components

12-32 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 021203 TERMINAL-RING, 3/16, 16 GA 18 22 023018 WIRE-16 GA,BLACK 1
(USED WITH TRAVEL CUTOUT)
2 013607 LIGHT-INDICATOR, 24V 1
23 021246 BOARD-TERMINAL, SCREW, #23 1
3 021204 TERMINAL-SLIP ON, 1/4 4
24 700475 SCREW-PH RD HD, 1/4-20 X 3/8 1
4 005422 CONNECTOR-INLINE INSUL 3
25 056116 CLAMP-CABLE 1
5 068231 SCREW-SL RD HD, 6-32 X 1/2 4
— 26 020703 SWITCH-LIMIT (USED WITH 1
6 DECAL, EMERGENCY POWER REF
DISCONNECT (FIGURE 12-9) TRAVEL CUTOUT)

7 023175 HARNESS ASSY 1 27 021210 TERMINAL-FORK, INSUL, #6, 2

14-16 GA (USED WITH TRAVEL
8 059416 NUT-HEX, 10-32 1
CUTOUT)
9 020698 SWITCH-PUSHBUTTON, RED 1
28 005433 CONNECTOR-SPLICE, INLINE 1
10 059421 NUT-HEX, 1/4-20 4 (USED WITH TRAVEL CUTOUT)
11 077209 WASHER-LOCK, SPLIT, 1/4 10 29 071375 SCREW-PH TR HD, 10-24 X 3/8 2
12 056127 CLAMP 1 30 077208 WASHER-LOCK, SPLIT, #12 3
13 070477 SCREW-PH RD HD, 1/4-20 X 5/8 1 31 056122 CLAMP-CABLE, 0.375 DIA 3
14 023209* HARNESS ASSY 1 33 020703 SWITCH-LIMIT 1
14 023240** HARNESS ASSY 1 34 504856 RESISTOR ASSY-2.2k 1
15 — SWITCH ASSEMBLY, REF 35 059412 NUT-HEX, 6-32 2
DIRECTIONAL (FIGURE 12-22)
36 005414 RELIEF-STRAIN, 3/4 2
15A — SWITCH ASSEMBLY, REF
37 071376 SCREW-PH TR HD, #10-32 X 1/2 1
DIRECTIONAL (FIGURE 12-21)
38 020697 SWITCH-PUSHBUTTON, BLACK 1
16 — . BOLT (FIGURE 12-21 REF
AND FIGURE 12-22) 39 057515 GROMMET 1

17 — . WASHER, LOCK (FIGURE 12-21 REF 40 020725 SWITCH-KEY 1

AND FIGURE 12-22) — 900621-01 . KEY SET A/R
18 — . WASHER, FLAT (FIGURE 12-21 REF 41 004730 ELECTRICAL CONTROL CABLE 21 FT
AND FIGURE 12-22) 42 057510** GROMMET-RUBBER, 2
19 — . NUT (FIGURE 12-21 REF 3/8 X 5/8, 1/4 TH
AND FIGURE 12-22) 43 059416† NUT-HEX, #10-32 2
20 072410 SCREW-THREAD CUTTING 2 43 074712†† SPACER-NYLON, #6 X 0.25 LG 2
21 021203 TERMINAL-RING, 3/16, 16 GA 1
(USED WITH TRAVEL CUTOUT)
* USED ON TRUCKS SERIAL NUMBER 334774 TO 351122.
** USED ON TRUCKS SERIAL NUMBER 351123 TO 374092.
† USED ON TRUCKS SERIAL NUMBER 334774 TO 356020.
†† USED ON TRUCKS SERIAL NUMBER 356021 TO 374092.

900980 12-33
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 356020

R5660

Figure 12-18 Chassis Mounted Electrical Components

12-34 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 005439 POWER DISCONNECT-24V 1 23 021204 TERMINAL-SLIP ON, 1/4 13
EMERGENCY 24 504116 SUPPRESSOR ASSY, SPIKE, 1
2 077209 WASHER-LOCK, SPLIT, 1/4 8 LOW SOL
3 063483 SCREW-HEX HD, 1/4-20 X 1-3/4 3 25 056113 TIE-WIRE, NYLON, LARGE A/R
4 504197-08 CABLE ASSY-BAT 1 26 076200 TUBING-ZIPPER 1
5 504197-07 CABLE ASSY, BAT 1 27 056120 TIE DELAY DOUBLE CLAMP 1
6 077030 WASHER, 1/4 X 9/16 X 16 GA 3 28 005427 PLASTIC CONNECTOR-MALE, 1
FOR CONTROL CABLES
7 063478 SCREW-HEX HD 1/4-20 X 3/4 2
29 005626 CONTACT-PIN 19
8 056135 CLAMP-LOOP, CUSHIONED, 2
1.25 DIA 30 023018 WIRE-16 GA, BLACK A/R
9 059421 NUT-HEX, 1/4-20 3 31 005627 CONTACT-SOCKET 6
10 021207 TERMINAL-RING, 5/16 2 32 005428 PLASTIC CONNECTOR-FEMALE, 1
FOR CONTROL CABLES
11 021203 TERMINAL-RING, 3/16, 16 GA 2
12 063486 SCREW-HEX HD, 1/4-20 X 2-1/4 2
33 — PANEL ASSEMBLY, ELECTRICAL, 1
SOLID STATE (FIGURE 12-28)
13 005401 CONNECTOR-BATT, 175 AMP 1
34 059529 NUT-HEX, JAM, 3/8-16 2
(GREY)
35 077211 WASHER-LOCK, SPLIT, 3/8 2
14 005450 HANDLE-CONN, BATTERY 1
36 077056 WASHER, 7/16 X 1 X 14GA 2
15 057512 GROMMET-RUBBER, 1-1/4 ID 2
37 005433 CONNECTOR-SPLICE, INLINE 1
16 075035 SPRING-ADJUSTING, CABLE 1
TENSION 38 023018 WIRE-16 GA BLACK A/R
17 005414 RELIEF-STRAIN, 3/4 1 39 — CABLE (FIGURE 12-15) 21 FT
18 504097 SUPPRESSOR ASSY-SPIKE 1 40 — BATTTERY (FIGURE 12-8) REF
19 023018 WIRE-16GA BLACK A/R 41 505935 CONNECTOR ASSY 1
20 — HORN-24V W/BRACKET REF 42 056113 TIE-WIRE, NYLON, LARGE 2
(FIGURE 12-5) 43 505936 BATTERY CABLE 1
21 — SWITCH-DEADMAN REF 44 005452 CONNECTOR-PIN, PANEL 1
(FIGURE 12-5) MOUNT
22 005422 CONNECTOR-INLINE INSUL 2 45 403713 SPACER 1

900980 12-35
 USED ON TRUCKS
SERIAL NUMBERS
356021 TO 374092

R6043

Figure 12-19 Chassis Mounted Electrical Components

12-36 900980
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — EPD CONTACTOR ASSY-SSCM REF 24 504116 SUPPRESSOR ASSY, SPIKE, 1
(FIGURE 12-29) LOW SOL
2 077064 WASHER, 0.641 X 1.062 X 7 GA 1 25 056113 TIE-WIRE, NYLON, LARGE A/R
3 059429 NUT-HEX, 3/8-16 2 26 076200 TUBING-ZIPPER 1
4 077211 WASHER-LOCK, SPLIT, 3/8 4 27 504197-10 CABLE ASSY, BATT 1
5 077056 WASHER, 7/16 X 1 X 14 GA 4 28 005427 PLASTIC CONNECTOR, MALE, 1
FOR CONTROL CABLES
6 077030 WASHER, 1/4 X 9/16 X 16 GA 2
29 005626 CONTACTS-MALE 19
7 063478 SCREW-HEX HD, 1/4-20 X 3/4 2
30 023018 WIRE-16 GA, BLACK A/R
8 056135 CLAMP-LOOP, CUSHIONED, 2
1.25 DIA 31 005627 CONTACT-SOCKET 7
9 059421 NUT-HEX, 1/4-20 2 32 005428 PLASTIC CONNECTOR, 1
FEMALE, FOR CONTROL
10 021207 TERMINAL-RING, 5/16 2
CABLES
11 021203 TERMINAL-RING, 3/16, 16 GA 2
33 — PANEL ASSEMBLY-ELECTRICAL, 1
12 063486 SCREW-HEX HD, 1/4-20 X 2-1/4 2
SOLID STATE (FIGURE 12-28)
13 005401 CONNECTOR-BATT, 175 AMP 1
34 059529 NUT-HEX, JAM, 3/8-16 2
(GREY)
35 077211 WASHER- LOCK, SPLIT, 3/8 4
14 005450 HANDLE-CONN, BATTERY 1
36 077056 WASHER, 7/16 X 1 X 14GA 4
15 057512 GROMMET-RUBBER, 1-1/4 ID 2
37 077209 WASHER-LOCK, SPLIT 1/4 4
16 075035 SPRING-ADJUSTING, CABLE 1
38 020697 SWITCH-PUSHBUTTON, BLACK 1
TENSION
39 074712 SPACER-NYLON, #6 X 0.25 LG 2
17 005414 RELIEF-STRAIN, 3/4 1
40 069465 SCREW-SL FL HD, #6-32 X 5/8 LG 2
18 504097 SUPPRESSOR ASSY-SPIKE 1
41 20574 DECAL-PUSH TO ENERGIZE 1
19 023014 WIRE-STRAINDED, 18 GA, RED A/R
42 503965-87 CABLE ASSY-2 AWG, 3/8-3/8, 1
20 — HORN-24V, W/BRACKET REF
(FIGURE 12-5) 43.75
43 403713 SPACER 1
21 — SWITCH-DEADMAN REF
(FIGURE 12-5) 44 005452 CONNECTOR-PIN, PANEL 1
MOUNT
22 005422 CONNECTOR-INLINE INSUL 2
23 021204 TERMINAL-SLIP ON, 1/4 13 45 — CABLE-CONTROL REF
(FIGURE 12-17)

900980 12-37
 R3155

Figure 12-20 Control Cable

INDEX PART NO.

NO. NO. PART NAME REQD.
1 004725 CABLE (ORDER 004730) 21 FT
2 057512 GROMMET-RUBBER, 1-1/4 ID 2
3 075035 SPRING-ADJUSTING, CABLE 1
TENSION
4 005414 STRAIN RELIEF 1
5 — BRACKET TENSION 1

12-38 900980
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 351122

R5303

Figure 12-21 Directional Switch Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505406 DIRECTIONAL SWITCH ASSY 1 10 402996 . SPACER 1
1 059421 . NUT-HEX, 1/4-20 (USED FOR 2 — 020777* . SWITCH CONTROL 1
SHIPPING) 11 — . . HOUSING 1
2 063485 . SCREW-HEX HD, 1/4-20 X 2 2 12 — . . RETURN SPRING ASSEMBLY 1
3 077209 . WASHER,-LOCK, SPLIT, 1/4 2 13 — . . COVER 1
4 077030 . WASHER, 5/16 X 3/4 X 16 GA 4 14 — . . CAM 1
5 800280 . GRIP-HANDLE 1 15 — . . HOUSING 1
6 504972 . CONTROL, HANDLE 1 16 901177 . . POTENTIOMETER 1
WELDM’T 17 — . . SCREW 1
7 020774 . SWITCH-ROCKER, SNAP-IN 1 18 005427 . PLASTIC CONNECTOR-MALE, 1
8 505058 . BEARING BLOCK ASSY 1 FOR CONTROL CABLES
9 061701 . E-RING 1 — 005626 . . CONTACTS--12V, 100A 9
* NO LONGER AVAILABLE. ORDER DIRECTIONAL SWITCH
PART NUMBER 505817.

900980 12-39
 USED ON TRUCKS
SERIAL NUMBERS
351123 TO 374092

R5758

Figure 12-22 Directional Switch Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505817 DIRECTIONAL SWITCH ASSY 1 11 020789 . SWITCH- DIRECTIONAL 1
1 059421 . NUT-HEX, 1/4-20 (USED FOR 2 12 — . . GEAR 1
SHIPPING) 13 — . . NUT 1
2 063485 . SCREW-HEX HD, 1/4-20 X 2 2 14 — . . WASHER, LOCK 1
3 077209 . WASHER-LOCK, SPLIT, 1/4 2 15 904184 . . POTENTIOMETER & GEAR 1
4 077030 . WASHER, 1/4 X 9/16 X 18 GA 4 ASSY
5 057503 . GRIP-HANDLE, FOAM 1 16 904183 . . MICRO SWITCH 2
6 504972 . CONTROL HANDLE WELDMT 1 17 904188 . . TORSION SPRING 1
7 020774 . SWITCH-ROCKER, SNAP-IN 1 18 005427 . PLASTIC CONNECTOR-MALE, 1
FOR CONTROL CABLES
8 505058 . BEARING BLOCK ASSY 1
9 061701 . E-RING 1
— 005626 . . CONTACT-PIN 5

10 402996 . SPACER 1

12-40 900980
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 342086

R3125

Figure 12-23 Hydraulic Pump and Motor Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016911 PUMP AND MOTOR 1 3 036107 . GASKET-PUMP TO MOTOR 1
(ORDER 016935) 4 900896-01 . PUMP WITH SAE PORTS 1
1 — . MOTOR ASSEMBLY REF 5 077210 . WASHER-LOCK, SPLIT, 5/16 4
(FIGURE 12-24) 6 063553 . SCREW-HEX HD, 5/16-18 X 3/4 4
2 056353 . DRIVE CONNECTOR-MOTOR 1
TO PUMP, 24V SYSTEMS

900980 12-41
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 342086

R1990

Figure 12-24 Motor Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 905046 PUMP MOTOR (ORDER 901547) 1 11 905033 . PROTECTIVE CAP 1
1 905047 . 24 VDC FIELD COIL 1 12 905034 . COMMUTATOR END SHIELD 1
2 905048 . ARMATURE 1 13 905037 . RETAINER 1
3 — . NUT USED 14 905038 . SCREW-FILLISTER HEAD 2
4 905045 . PIN 1 15 905039 . SCREW-FILLISTER HEAD 4
5 905051 . SCREW-FLAT HEAD 4 16 905040 . WASHER-PRING LOCK 4
6 905052 . RETAINER 1 17 905041 . SCREW-FILLISTER HEAD 4
7 900495 . DRIVE END BEARING 2 18 905042 . BRUSH HOLDER 1
8 905030 . SPRING WASHER 1 19 905043 . SPIRAL SPRING 4
9 605031 . RETAINER 1 20 905044 . CARBON BRUSH SET 1
10 905032 . TERMINAL STUD PKG. 1

12-42 900980
 USED ON TRUCKS
SERIAL NUMBERS
342087 TO 360933
EXCEPT 360858

R5304

Figure 12-25 Hydraulic Pump and Motor Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016935 PUMP&MOTOR ASSY 1 9 — . . DRIVE END HOUSING 1
1 — . SCREW 4 10 901602 . . BALL BEARING 1
2 — . WASHER-LOCK 4 11 — . . ARMATURE 1
3 900896-01 . PUMP WITH SAE PORTS 1 12 — . . FIELD COIL 1
4 036107 . GASKET-PUMP TO MOTOR 1 13 901600 . . BRUSH SET 1
5 056353 . DRIVE CONNECTOR-MOTOR 1 14 — . . THRUST WASHER PACKAGE 1
TO PUMP, 24V SYSTEMS 15 901601 . . COMMUTATOR END HEAD 1
6 020715 . SOLENOID-24V, CONT DUTY 1 WITH NEEDLE BEARING (NO
LONGER AVAILABLE)
7 — . SCREW 2
8 — . WASHER-LOCK 2
16 — . THRU BOLT 2

— 901547 . 24V PUMP MOTOR (ORDER 1

901623)

900980 12-43
 USED ON TRUCKS
SERIAL NUMBERS
360858,
360933 TO 374092

1 3
4

R6025

Figure 12-26 Hydraulic Pump and Motor Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016940-02 PUMP AND MOTOR ASSEMBLY 1 4 906006 . PUMP COUPLING 1
1 906003 . 24V SOLENOID 1 5 906007 . 24V MOTOR ASSY 1
2 906004 . PUMP ASSY 1 6 906008 . BRUSH SET 1
3 906005 . PUMP GASKET 1

12-44 900980
 R5689

Figure 12-27 Drive Motor Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016048 MOTOR-DRIVE, 24V 1 9 9016118 . INSULATOR KIT 2
1 901246 . BAND-COVER 1 10 — . SCREW-HEX POLE SHOE, 8
5/16 X 24-1
2 901614 . COMMUTATOR END HEAD 1
11 901619 . FIELD COIL SET W/INSULATOR 1
3 901615 . BRUSH HOLDER W/SPRINGS 1
12 901620 . ARMATURE ASSY 1
4 900136 . BRUSH SPRING SET 8
13 901239 . SEAL-SHAFT, DRIVE END 1
5 901616 . DRIVE MTR BRUSH SET OF 4 4
— 14 901241 . BEARING (ORDER 051136) 1
6 . WASHER-SPRING 1
7 901244 . BEARING-BALL, SEALED 1 15 901240 . HEAD ASSY, DRIVE END 1

8 901617 . CONNECTOR 2

900980 12-45
 R5519

Figure 12-28 Contactor Panel Assembly

12-46 900980
 INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 505404 PANEL ASSY 1 19 008906 . FUSE-300 AMP 1
2 504277-10 . CABLE ASSY., BATTERY 1 20 056507 . DECAL-FUSE, 300 AMP, 0.020 1
ALUM
3 059421 . NUT-HEX, 1/4-20 2
21 503965-70 . CABLE ASSY, S2 1
4 403238 . PANEL-ELECT, TRANSISTOR, E 1
— 22 070475 . SCREW-PH RD HD, 1/4-20 X 3/8 4
5 . CONTACTOR-24V, 100A 2
(FIGURE 12-30) 23 055976 . DIODE-400V, 1A 2
6 005467-02 . CONTROLLER-SPEED, 1 24 503965-40 . CABLE ASSY, 2AWG, 1/4-3/8,38 2
ELEC., 24V 25 063552 . SCREW-HEX HD, 5/16-18 X 5/8 2
7 010613 . TUBING-INSULATING, 0.053 ID A/R 26 059426 . NUT-HEX, 5/16-18 4
8 503965-81 . CABLE ASSY, (A1) 1 27 077210 . WASHER-LOCK, SPLIT, 5/16 4
9 503965-11 . CABLE ASSY 1 28 063553 . SCREW, HEX HD, 5/16-18 X 3/4 2
10 070491 . SCREW-PH RD HD, #8-32 X 7/8 4 29 008904 . HOLDER-FUSE, 1/4 X 1 1
11 077205 . WASHER-LOCK, SPLIT, #8 4 30 068177 . SCREW-SL RD HD, #5-40 X 3/8 1
12 077032 . WASHER, 3/16 X 1/2 X 13 GA 4 31 077203 . WASHER-LOCK, SPLIT, #5 1
13 401181 . BUSSBAR 2 32 056504 . DECAL-FUSE, 15A 1
14 010614 . STANDOFF-INSULATOR 2 33 008910 . FUSE-15 AMP, 1/4 X 1 1
15 077105 . WASHER-BRASS, 4 34 023208 . WIRE HARNESS ASSY 1
0.337 X 0.75 X 1/16 35 503965-82 . CABLE ASSY, POS 1
16 075620 . STUD-THRD, BRASS, 2 36 503965-34 . CABLE ASSY, 2 AWG, 1/4-3/8,11 1
1/4-20 X 1-1/4
37 503965-06 . CABLE ASSY, 2 AWG, 1/4-3/8,12 1
17 077209 . WASHER-LOCK, SPILT, 1/4 6
38 04857-12 . CABLE ASSY 1
18 069477 . SCREW-PH FL HD, 1/4-20 X 1/2 2

900980 12-47
 USED ON TRUCKS
SERIAL NUMBERS
356021 TO 374092

R6044

Figure 12-29 EPD Contactor Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 505851 EPD CONTACTOR ASSY-SSCM 1 8 077209 . WASHER-LOCK, SPLIT, 1/4 4
2 005670-02 . CONTACTOR ASSY 1 9 059421 . NUT-HEX, 1/4-20 4
3 018409-02 . RELAY-MOUNT, FLANGE, 24V 1 10 068177 . SCREW-SL, RD HD, 5-40 X 3/8 2
4 404090 . PANEL 1 11 077203 . WASHER-LOCK, SPLIT, #5 2
5 023246 . WIRE A/R 12 077007 . WASHER, 5-32 X 3/8 X 18 GA 2
6 505852 . HARNESS 1
7 010613 . SCREW-HEX HD, 1/4-20 X 1/2 4

12-48 900980
 NOTES

900980 12-49
 CONTACTOR TIP KIT
PART NUMBER
900531-09
CONTAINS:
ITEM QTY
2 1
5 1
13 1
24 1
25 1

R3110

Figure 12-30 Double Pole Contactor

12-50 900980
 PART NO. PART NO.
NO. PART NAME REQD. NO. PART NAME REQD.
— 005657 CONTACTOR-24V, 100A 1 16 905010 . BASE MOLDING 1
1 401181 . BUSSBAR 2 17 — . BOLT 1
2 905026* . STATIONARY CONTACT TIP 1 18 — . WASHER-FLAT 1
3 905017 . STUD FOR TOP OF 1 19 9050224 . COIL FRAME 1
CONTACTOR 20 — . BOLT 1
4 905016 . SPRING OF CONTACTOR 2 21 — . WASHER-FLAT 1
5 905018* . CONTACTOR TIP 1 22 — . WASHER-LOCK, SPLIT 1
6 905019 . ARMATURE PLATE 1 23 — . NUT 1
7 905020 . POLE PIECE 1 24 905012* . BRAID ASSY 1
8 905028 . 24 VOLT COIL 1 25 905015* . ARMATURE PLATE CLIP 1
9 — . BOLT 1 26 — . NUT 1
10 — . WASHER-FLAT 1 27 — . BOLT 1
11 — . WASHER-LOCK, SPLIT 1 28 905027 . REAR MOUNTING 1
12 — . NUT 1 29 — . WASHER-FLAT 1
13 905022* . FRONT CONTACT TIP 1 30 — . WASHER-LOCK, SPLIT
14 905023 . SPACER FOR CONTACTOR 1 31 — . NUT 1
15 905025 . BLOWOUT MOLDING 1

* CONTACTOR TIP KIT 900531-09. ONE KIT REPAIRS ONE

CONTACTOR.

900980 12-51
 R6045

Figure 12-31 400 Amp Contactor Service Kit

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 906000 SERVICE KIT-400 AMP 1 3 BRG1403 . BRIDGE ASSY 1
CONTACTOR 4 BSH0007 . BUSHING 1
1 WNM0002 . WASHER 1 5 BBR1403 . BUSSBAR 2
2 SPR0001 . SPRING 1

12-52 900980
 NOTES

900980 12-53
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 344374

R3157

Figure 12-32 Timer Charger Installation

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — BATTERY CHARGER, 120V 1 12 005422 CONNECTOR-INLET, INSUL 2
1 PHASE, 60 HZ (FIGURE 12-33) 13 021204 TERMINAL-SLIP ON, 1/4 9
1 — BATTERY CHARGER, 240V 1 14 021237 TERMINAL-RING, #10, UNINSUL 4
1 PHASE, 50 HZ (FIGURE 12-33) 12-10
1 004957-03 BATTERY CHARGER, 240V 1 15 900462 AMMETER W/NUMBERS 0-40 1
1 PHASE, 60 HZ
16 068231 SCREW-SL RD HD, 6-32 X 1/2 3
2 077031 WASHER, 5/16 X 3/4 X 16 GA 4
17 005454 CONNECTOR-INLET, FLANGE, 1
3 077209 WASHER-LOCK, SPLIT, 1/4 4 120V
4 070475 SCREW-PH RD HD, 1/4-20 X 3/8 4 17 005455 CONNECTOR-INLET, FLANGE, 1
5 021206 TERMINAL-RING, 1/4, 16 GA 6 250V
6 005401 CONNECTOR-BATT, 175 AMP 1 18 023018 WIRE-16GA, BLACK 4
(GREY) 19 900379 PILOT LIGHT, RED, ROUND 1
7 023011 WIRE-10 GA, BLACK A/R 20 901021 INLINE FUSE HOLDER 1
7A 023010 WIRE-10 GA, RED A/R 21 900376 KNOB, TIMER 1
8 004021 BUSHING-CABLE WELL, 1/0-4 2 22 900497 SCREW-8/32 X 1/4 3
9 402264 SPACER 1 23 900475 TIMER DIAL PLATE 1
10 901030 AC FUSE, 15AMP, AGC15 1 24 005810 CORD, CHARGER, 120V, 1-60HZ 1
10 900847 AC FUSE, 10A 1 24 504599 CORD, CHARGER, 240V, 1-50HZ 1
11 900375 TIMER-12 HOUR, NO KNOBS 1
11 900749 TIMER-50 CYCLE 1

12-54 900980
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 344374

R3158

Figure 12-33 Timer Charger

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 004957-01* CHARGER-BATT, 15A, 120V 1 9 059416 . NUT-HEX, 10-3 10
— 004957-02 CHARGER-BATT, 15A, 240V 1 10 901026 . INSULATOR (ORDER 901028) 1
1 901023 . TRANSFORMER FOR 1 11 901028 . TERMINAL BOARD FOR 1
004957-01 004957-01
1 901024 . TRANSFORMER FOR 1 11 901031 . TERMINAL BOARD FOR 1
004957-02 004957-02
2 900564 . SCREW-SELF-TAPPING, 4 12 901029 . NUT- HEX, 10-32, SMALL 2
10-32 X 3/8 13 901027 . DIODE ASSY 1
3 900466 . STRAP 2 14 — . RECTIFIER 1
4 900465 . CONDENSER (ORDER 900385) 1 15 — . INSULATOR 1
5 — . NAMEPLATE 1 16 — . SPACER-INSULATOR, NYLON 2
6 900507 . SCREW-NO. 4 X 3/16 2 17 077207 . WASHER-LOCK, SPLIT, #10 4
7 068408 . SCREW-10-32 X 1/2 9 18 901022 . CIRCUIT BREAKER 1
8 077505 . WASHER-LOCK, SPLIT #10 6
* ORDER “SMART” CHARGER PART NUMBER 004977-01,
FIGURE 12-34.

900980 12-55
 USED ON TRUCKS
SERIAL NUMBERS
334774 TO 344374

R5692

Figure 12-34 Auto Charger 120 VAC

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 004977-01* CHARGER-24V, 15A, 120V/1, 1 12 005454 . CONNECTOR-INLET FLANGE, 1
AUTO 120V
1 — . TRANSFORMER ASSY 1 13 900379 . PILOT LIGHT-RED, ROUND 1
2 077031 . WASHER, 5/16 X 3/4 X 16 GA 4 14 907112 . CONTROL CARD CIRCUIT 1
BOARD
3 077209 . WASHER-LOCK, SPLIT, 1/4 4
15 907077 . TRIAC, 12V 1
4 070475 . SCREW-PN RD HD, 2
1/4-20 X 3/8 16 907078 . CONTROL CARD 1
TRANSFORMER
5 005401 . CONNECTOR-BATT, 175 AMP 1
(GREY) 17 067414 . SCREW-PN HD, #10-24 X 3/8 2
5A 005655-01 . CONTACT-SB, BATT CONN, 2 18 077208 . WASHER-LOCK, SPLIT, #12 2
175 AMP 19 005810 . CORD-CHARGER, 1
6 004021 . BUSHING-CABLE WELL, 1/0-4 2 120V-1-60 HZ
7 402264 . SPACER 1 * USED TO REPLACE TIMER VERSION CHARGER PART
NUMBER 004957-01. HOWEVER THE CHARGER MUST
8 900847 . AC FUSE-10A 1
BE DISASSEMBLED, MOUNTING HOLES DRILLED FOR
9 009504 . HOLDER-FUSE, IN-LINE 1
TRANSFORMER CONTROL CARD, AND THE COMPO-
10 900462 . AMMETER W/NUMBERS 0-40 1 NENTS OF THE CHARGER MOUNTED ON VARIOUS
11 068231 . SCREW-SL RD HD, 6-32 X 1/2 2 PANELS AS SHOWN.

12-56 900980
 USED ON TRUCKS SEE SUPPLEMENT 335 FOR
SERIAL NUMBERS ADDITIONAL INFORMATION
356021 TO 374092 ON CHARGER 004978

3
4 19 TO
CONNECTOR
(ITEM 7)
TO
CONNECTOR
(ITEM 7)

10 19
9 12
7 20
11 TO
8 AMMETER
16
18
1
2
15
3
5 3 (BLACK)
(RED) 6 TO
17 14 13
CONNECTOR
(ITEM 7)

R5298

Figure 12-35 Auto Charger 004978 and 004980

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 004978 AUTO CHARGER (120 VAC) 1 10 059429 . NUT- HEX, 3/8-16 1
— 004980 AUTO CHARGER (240 VAC) 1 11 065476 . SCREW-HEX HD, 1/4-20 X 1/2 1
1 059412 . NUT-HEX, 6-32 2 12 008910 . FUSE-15 AMP, 1/4 X 1 1
2 077204 . WASHER-LOCK, SPLIT, #6 2 13 059421 . NUT-HEX, 1/4-20 1
3 505640 . CONNECTOR ASSY-CHARGER 1 14 077209 . WASHER- LOCK, SPLIT, 1/4 1
4 402264 . SPACER 1 15 077064 . WASHER, 0.641 X 1.062 X 7 GA 2
5 015609 . AMMETER-12V, 20A 1 16 004978 . CHARGER-24V, 15A, AUTO, 1
120 VAC
6 005810 . CORD ASSY-CHARGER, 1
120V-1-60 HZ 16 004980 . CHARGER-24V, 15A, AUTO, 1
220 VAC
6 5004599 . CORD ASSY-CHARGER, 1
240V-1-50 HZ 17 901603 . . CIRCUIT BOARD WITH HEAT 1
SINK
7 005454 . CONNECTOR-INLET FLANGE, 1
120V 18 901604 . . CIRCUIT BREAKER 1
7 005455 . CONNECTOR-INLET FLANGE, 1 19 — . . PILOT LIGHT-RED, ROUND 1
240V (PART OF ITEM 16)
8 068231 . SCREW-SL RD HD, 6-32 X 1/2 2 20 505764-01 . . FUSE HOLDER ASSY 1
9 007211 . WASHER-LOCK, SPLIT, 3/8 1

900980 12-57
 R3158A

Figure 12-36 Optional Lift Limit Override

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 021210 TERMINAL-FORK, INSUL #6, 2 7 021203 TERMINAL-RING, 3/16, 16 GA 1
14-16 GA 8 068231 SCREW-SL RD HD, 6-32 X 1/2 2
2 020703 SWITCH-LIMIT 1 9 056557 DECAL-LIFT-LIMIT OVERRIDE 1
3 005405 RELIEF-STRAIN, 3/8 1 10 074712 SPACER-YLON 2
4 068239 SCREW, 6-32 X 2-1/2 SLOTTED 2 11 020697 SWITCH, PUSHBUTTON, BLACK 1
5 023018 WIRE-16 GA BLACK A/R 12 021204 TERMINAL-SLIP ON, 1/4 2
6 055433 CONNECTOR-SPLICE, INLINE 1

12-58 900980
 R3159

Figure 12-37 Optional Hour Meter

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 068179 SCREW-SL RD HD, 5-40 X 5/8 3 7 021204 TERMINAL-SLIDEON, 1/4 6
2 015604 METER-HOUR 1 8 005422 CONNECTOR-INLINE, INSUL 6
3 5040116 SUPPRESSOR ASSY-SPIKE, 1 9 005987 DIODE ASSY 1
LOW SOL 10 068177 SCREW-SL RD HD, 5-40 X 3/8 2
4 077203 WASHER-LOCK, SPLIT #5 3 11 023018 WIRE-16 GA, BLACK A/R
5 059410 NUT-HEX, 5-40 3 12 021203 TERMINAL-RING, 3/16, 16 GA 4
6 010610 PAD- INSUL DIODE 1

900980 12-59
 R5755

Figure 12-38 Optional Battery Capacity Indicator Schematic

WITH LIFT LOCKOUT WITH LIFT LOCKOUT

INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 021718 TERMINAL-SLIP ON, 1/4 INSUL 3 1 021718 TERMINAL-SLIP ON, 1/4 INSUL 2
2 021203 TERMINAL- RING, 3.16, 16 GA 3 2 021203 TERMINAL-RING, 3/16, 16 GA 3
3 023018 WIRE-16 GA, BLACK, 9 FOOT A/R 3 023018 WIRE-16 GA, BLACK, 9 FOOT A/R

12-60 900980
 R5754

Figure 12-39 Optional Battery Capacity Indicator

WITH LIFT LOCKOUT WITH LIFT LOCKOUT

INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 010618-02 METER-CAP BATT, 24V 1 1 010618-02 METER-CAP BATT, 24V, 1
2 — . BRACKET, METER 1 2 — . BRACKET, METER 1
3 — . NUT 2 3 — . NUT 2

900980 12-61
 R3131

Figure 12-40 Optional Flashing Red Light

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 013610 GUARD-AMP 1 8 077209 WASHER-LOCK, SPLIT, 1/4 2
2 063480 SCREW-HEX HD,M1/4-20 X 1 2 9 059421 NUT- HEX, 1/4-20 2
3 077031 WASHER, 5/16 X 3/4 X 16 GA 2 10 059416 NUT-HEX, 10-32 2
4 071376 SCREW-PH TR HD, 10-32 X 1/2 2 11 077207 WASHER-LOCK, SPLIT, #10 2
5 013609-02 LAMP-STROBE, 12&24V, RED 1 12 057510 GROMMET-RUBBER, 1
3/8 X 5/8, 1/4 TH
6 901497 . BULB (OLDER LIGHTS) 1
13 056122 CLAMP (FOR FUSE WIRES) 1
7 904186 . BULB (NEWER LIGHGTS) 1

12-62 900980
 R3132

Figure 12-41 Optional Flashing Red Light Wiring Diagram

INDEX PART NO.

NO. NO. PART NAME REQD.
1 005627 CONTACT-SOCKET 1
2 023018 WIRE-16 GA, BLACK (7 FOOT) A/R
3 021204 TERMINAL-SLIP ON, 1/4 4
4 005422 CONNECTOR-INLINE, INSUL 2
5 005649 CONNECTOR 1
6 005433 SPLICE, INLINE (USED IF 1
EXTERNAL FUSE USED)

900980 12-63
 R5756

Figure 12-42 Optional Side Guide Rollers

INDEX PART NO.

NO. NO. PART NAME REQD.
1 403009 SPINDLE-ROLLER 4
2 051136 BEARING-BALL, (3205), 4
2 SEALS
3 403008 ROLLER-GUIDE 4
4 061725 RING-SNAP, EXT, 1 DIA 4
5 061824 RING-SNAP, INT, 2-1/16 4

12-64 900980
 R784

Figure 12-43 Optional Safety Harness and Lanyard

INDEX PART NO.

NO. NO. PART NAME REQD.
1 074006 LANYARD-SAFETY, 6 FT LG 1
2 074003 SAFETY HARNESS 1
(ORDER 074010)

900980 12-65
 R3160

Figure 12-44 Standard Safety Belt and Lanyard

INDEX PART NO.

NO. NO. PART NAME REQD.
1 074006 LANYARD-SAFETY, 6 FT LG 1
2 074008 BELT-SAFETY, SGL D-RING 1
MEDIUM

12-66 900980
 R3161

Figure 12-45 Optional Safety Belt

INDEX PART NO.

NO. NO. PART NAME REQD.
1 074002 BELT-SAFETY, DOUBLE D-RING 1
2 074602 HOOK-SNAP, LOCKING, 2
FORGED ALLOY
3 055628 CHAIN-3/4 DIA 2
4 074603 COLD SHUT 4

900980 12-67
 R2103

Figure 12-46 Optional Slip On Platform

INDEX PART NO.

NO. NO. PART NAME REQD.
1 503502-07 PLATEFORM INSTL-SLIP ON, 1
32 X 36 LG
1 503502-08 PLATEFORM INSTL-SLIP ON, 1
32 X 42 LG
1 503502-09 PLATEFORM INSTL-SLIP ON, 1
32 X 48 LG
2 055628 CHANI-3/16 DIA (SPECIFY A/R
LENGTH
3 074602 COLD SHUT 3
4 074603 COLD SHUT 6
5 063715 SCREW-HEX HD, 2
1/2-13 X 1-3/4 LG
6 077104 WASHER-FLAT, STANDARD, 1/2 4
7 059639 NUT-LOCK, HEX, 1/2-13 2

12-68 900980
 R5695

Figure 12-47 Optional Quick Disconnect Cables

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505623 QUICK DISCON 1 2 505621 CONNECTOR ASSY-BATTERY 1
INSTL-BATTERY 3 505649 CORD ASSY-CHARGING, 1
1 505622 CONNECTOR ASSY-BATTERY 4 EXTERNAL

900980 12-69
 NOTES

12-70 900980
Big Joe Manufacturing Company