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
and authorized to do so and have read all warnings
and instructions in operator's manual and on this truck.
Do not operate this truck until you have checked its
condition. Give special attention to Tires, Horn, Lights,
Battery, Controller, Lift System, (including forks or
attachments, chains, cables and limit switches),
Brakes, Steering Mechanism, Guards and Safety
Devices.
Operate truck only from designated operating position.
Never place any part of your body into the mast struc-
ture, between the mast and the truck, or outside the
truck. Put on operator's safety harness when so
equipped.
Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
cross aisles and wherever vision is obstructed.
Start, stop, travel, steer and brake smoothly. Slow
down for turns and on uneven or slippery surfaces that
could cause truck to slide or overturn. Use special
care when traveling without load as the risk of overturn
may be greater.
Travel with lifting mechanism as low as possible.
Always look in direction of travel. Keep a clear view,
and when load interferes with visibility, travel with load
or lifting mechanism trailing (except when climbing
ramps).
Use special care when operating on ramps. travel
slowly, and do not angle or turn. When truck is loaded
iv
travel with load uphill. When truck is empty, travel with
lifting mechanism downhill.
Do not overload truck. Check capacity plate for load
weight and load center information.
Before lifting be sure load is centered, forks are com-
pletely under load and load is as far back toward oper-
ator's platform as possible.
Do not handle unstable or loosely stacked loads. Use
special care when handling long, high or wide loads to
avoid losing the load, striking bystanders, or tipping
the truck.
Do not operate truck without an overhead guard.
Elevate forks or other lifting mechanism only to pick up
or stack a load. Watch out for obstructions, especially
overhead.
Do not lift personnel except on a securely attached
specially designed Work Platform. Use extreme care
when lifting personnel. Make sure mast is vertical.
Place truck controls in neutral and apply brakes. Lift
and lower smoothly. Remain in operating position or
immediate vicinity as long as personnel are on the
Work Platform.
Do not allow anyone to stand or pass under load or lift-
ing mechanism.
Before getting off truck, neutralize travel control. Fully
lower lifting mechanism and set brake. When leaving
truck unattended, also shut off power.
900980
 PREPARATION FOR USE

Upon receipt, visually inspect vehicle and battery
charger. If any damage is found, report it to the carrier
and to your Big Joe dealer immediately.
Remove cardboard banded over carriage and over
base of truck. Check vehicle and battery charger for
scratches and dents. Check to make sure that the lift
chains are secure. Inspect for oil leaks and loose wir-
ing connections. Make certain that all accessories and
attachments that were ordered are supplied.
Provisions have been made to prevent the lift carriage
from being moved from a predetermined position dur-
ing transit. These include the following:
1. The positive lead of the lift pump has been dis-
connected.
2. The lift carriage is banded down to the straddle
legs.
To place the lift carriage in operation, perform the fol-
lowing steps:
1. Cut banding which holds the lift carriage to strad-
dles.
2. Remove 4 x 4 blocks and banding from carriage.
3. Check battery, recharge if necessary and con-
nect. If the vehicle was ordered without a battery,
a freshly charged battery of adequate size and
proper weight must be installed. Refer to "Battery
Care" in SECTION 3 for battery checking instruc-
tions.
CAUTION: The batteries are extremely heavy (over
100 pounds each). Do not attempt
removal or installation without assistance
or proper equipment.
4. Connect positive lead to pump motor (inside con-
trol cabinet).
5. The lift carriage is now ready for normal opera-
tion.
Refer to SECTION 2 for operating instructions and test
the following controls:
Directional Switch
Brake Pedal
Braking with Directional Switch
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.
This section gives detailed operating instructions for
the counterbalanced stock selector lift truck. The vari-
ous functional systems are first explained to provide a
broad understanding of how the vehicle operates, fol-
lowed by step-by-step operating procedures. Routine
precautions are included for safe operation.
2-2. OPERATING PRECAUTIONS.
WARNING: Improper operation of the stock selector
lift truck may result in operator injury, or
load and/or lift truck damage. Observe
the following precautions when operating
the stock selector lift truck.
1. Do not operate this truck unless you have been
trained and authorized to do so, and have read
and understand all warnings and instructions in
this manual and on the lift truck.
2. Do not operate this truck until the periodic inspec-
tion or service has been completed. See
Table 3-1.
3. Overloading will result in damage to the hydraulic
system and lift mechanism. Do not exceed the
rated lifting capacity.
SAFE
R3814
Figure 2-1 Load Center
900980
4. Do not handle unstable or loosely stacked loads.
Use special care when handling long, high, or
wide loads to avoid tipping, loss of load, or striking
bystanders.
5. Center and carry the load as far back toward the
lift carriage as possible. Do not pick up loads on
the tips of the forks. The center-of-gravity of the
load must not exceed the load center listed on the
name plate. See Figure 2-1 for load center limita-
tions.
6. Pick up loads on both forks. Do not pick up loads
on only one fork.
7. Always lower load when traveling to increase
vehicle stability.
8. When stacking pallets in racks, it is necessary to
move the load in the raised position. Move slowly
and use care when turning at a right angle.
9. Check for obstructions when raising or lowering
the lift carriage.
10. Apply the mechanical brake gently except in
cases of emergency.
11. Observe applicable traffic regulations. Yield right
of way to pedestrians. Slow down and sound horn
at cross aisles and wherever vision is obstructed.
UNSAFE
2-1
2-3. BEFORE OPERATION
Table 2-1 covers important inspection points on SSCM
lift truck which should be checked prior to operation.
Depending on use, some trucks may require additional
checks.
Figure 2-2 shows a sample format for a Operator
Checklist, which can be modified as necessary to fit
your operation.
WARNING: Periodic maintenance of this truck by a
QUALIFIED TECHNICIAN is required.
CAUTION: A QUALIFIED SERVICE TECHNICIAN
should check the truck monthly for
Table 2-1 Operator Checks
ITEM PROCEDURE
Transmission Check for signs of fluid leakage.
and hydraulic
systems.
Forks Check for cracks and damage;
and, that they are structurally
secure.
Chains, cables Check that they are in place,
and hoses secured correctly, functioning
properly and free of binding or
damage.
Guards Check that safety guards are in
place, properly secured and not
damaged.
Safety signs Check that warning labels,
nameplate, etc., are in good
condition and legible.
Horn Check that horn sounds when
operated.
Steering Check for binding or looseness in
steering wheel when steering.
Travel controls Check that speed control lever
operates in all speed ranges in
forward and reverse.
2-2
proper lubrication, proper fluid levels,
brake maintenance, motor maintenance
and other areas specified in the SEC-
TION 3.
WARNING: If the truck is found to be unsafe and in
need of repair, or contributes to an
unsafe condition, report it immediately to
the designated authority. Do not operate
it until it has been restored to a safe
operating condition. Do not make any
unauthorized repairs or adjustments. All
service must be performed by a qualified
maintenance technician.
ITEM PROCEDURE
Wheels Check drive wheel for cracks or
damage. Move truck to check
load wheels for freedom of rota-
tion.
Hydraulic con- Check operation of lift and lower
trols to their maximum positions.
Brakes Check that brakes release when
the brake pedal is depressed.
Deadman/Park- Check that brake pedal raises to
ing brake upright position when released
and brake applies.
Battery discon- Check that battery can be
nect disconnected and reconnected.
Check for connector damage.
Battery charge Check that battery capacity
meter (if equipped) is on “F”.
High speed limit Allow for enough space to oper-
switch ate truck in high speed. Elevate
forks approximately two feet,
then test drive truck to check if
high speed is cut out.
900980
 R5659

Figure 2-2 Sample of Operator Check List

900980 2-3
2-4. INSTRUMENTS AND CONTROLS (Figure 2-3)
Key Switch (1): Used to prevent unauthorized per-
sonnel from operating the lift truck.
Brake Pedal (2): Used to release the mechanical
brake when depressed and engage the brake when
released.
Steering Wheel (3): Used to control the direction of
travel.
Directional Control (4): Used to control the direction
and speed of the truck.
Lowering Pushbutton (5): Used to lower the opera-
tor's platform and forks from the raised position.
Emergency Power Disconnect Switch (6): Used to
disengage the emergency power disconnect located
inside the base and frame compartment, disconnect-
ing all power to the truck in case of an emergency.
Horn Pushbutton (7): Used to sound the horn.
Steer-Wheel Position Indicator (8): Used to indicate
the position of forward travel of the drive wheel.
Optional Hourmeter (9): Used to record the accumu-
lated hours that electrical energy is being drawn from
the battery to run the pump and drive motors.
Optional Flasher Switch (10): Used to control the
optional flashing red light.
Lift Pushbutton (11): Used to raise the operator's
platform and forks from the lower position.
Optional Pallet Clamp (12): Used to secure a pallet
on the forks.
Optional Lift Limit Override (13): Used to override
the lift limit switch allowing additional lifting of the oper-
ator's platform and forks.
Battery Capacity Indicator (14): Used to monitor the
battery discharge rate to indicate the remaining battery
capacity.
Optional Manual Lowering Lever (15): Used to man-
ually lower the operator's platform and forks in case of
a power loss.
Charger (16): Used to recharge the battery.
EPD Energize Switch (17): Trucks serial number
334774 to 356020, used to energize the truck after an
emergency power disconnect.
EPD Energize Switch (18): Trucks serial number
356021 to 374092, used to energize the truck after an
emergency power disconnect.
2-4
2-5. OPERATION
2-5.1. Driving and Stopping Procedures
(Figure 2-3)
Proceed as follows to start and stop the stock selector
lift truck:
1. Step on the platform facing the control console
and turn the key switch (1) on.
2. Step on the brake pedal (2) to release the brake
and to activate the electrical controls.
3. Note position of the drive wheel position indicator
(8).
4. Place one hand on the steering wheel (3) and be
prepared to steer the vehicle in the desired direc-
tion.
5. To move forward, slowly twist the directional con-
trol (4) forward. The vehicle will creep forward.
Twisting the control further causes the speed to
increase.
6. To stop, lift foot slowly from the brake pedal (2) as
you release the directional control (4).
NOTE: Additional procedures for stopping are
described in paragraph 2-5.2.
7. To stop rapidly when an emergency exists, quickly
lift foot from brake pedal.
WARNING: Except in an emergency, do not stop
suddenly. Lift foot slowly from the brake
pedal.
8. To move in reverse, slowly twist the directional
control (4) to the rear. Twisting the control further
causes the speed to increase.
NOTE: Vehicle direction may be reversed while mov-
ing. The transistor speed control unit will
cycle the motor to a stop and a reverse in a
timed sequence without danger to the equip-
ment. Exercise caution when doing so, espe-
cially when traveling at maximum speed.
2-5.2. Braking (Figure 2-3)
Following are the various methods for stopping the
stock selector lift truck:
Release the directional control (4) and lift your foot
from the brake pedal (2).
Using the directional control (4), reverse direction.
Release the directional control (4) and allow the vehi-
cle to coast to a stop.
900980
 R3154
Figure 2-3 Operator’s Controls
2-5.3. Operating Lift (Figure 2-3)
Proceed as follows to raise and lower the lift carriage:
1. Step onto the platform and stand near the control
station.
NOTE: It is not necessary to release the brake. For
maximum safety, leave the brake on.
2. Turn on the key switch (1).
WARNING: Check the space above your head and
above the entire carriage to be sure that
the platform mast or load will not hit any
obstructions while being raised.
3. To raise the lift carriage, depress the lift pushbut-
ton switch (11).
900980
NOTE: The lift carriage will rise as long as the lift
pushbutton is depressed, or until the lift car-
riage reaches maximum height.
4. Release the lift pushbutton when the lift carriage
reaches the desired height.
5. To lower the lift carriage, press the lower pushbut-
ton switch (5).
6. When the lift carriage reaches the desired level,
release the lower pushbutton switch (5).
2-5.4. Emergency Lowering
In case of power loss a manually operated lowering
valve (43, Figure 12-14) is located adjacent to the
pump motor on standard models. The valve is accessi-
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.
2-5
An optional carriage operated manual lowering valve
is installed on some trucks. This lowering valve allows
an operator on a raised carriage to lower the carriage
at a controlled rate when power is not available such
as when the Emergency Power Disconnect has been
activated. When this option is installed a red lever is
also added to the lowering valve (28, Figure 12-15) on
the chassis. This lever is accessible by opening the
upper access door. Pressing the lever will cause the
carriage to descend.
2-5.5. Emergency Power Disconnect (Figure 2-3)
In an emergency, all power can be turned off at once
by depressing the EMERGENCY POWER DISCON-
NECT (EPD) PUSHBUTTON SWITCH (6). Once this
circuit is actuated, none of the electrical controls will
operate until the circuit is reset, but the lift carriage can
be lowered using the manual lowering controls. (See
paragraph 2-5.4.)
CAUTION: For trucks Serial Number 334774 to
356020, before disconnecting the bat-
tery, make sure you can open the electri-
cal compartment door to reset the EPD
circuit.
To make the vehicle operable, the emergency power
disconnect must be reset. For trucks Serial Number
334774 to 356020, the emergency power disconnect
reset plunger is located on a bracket behind the upper
access door. For trucks Serial Number 356021 to
374092, the emergency power reset is reset by press-
ing the PUSH TO ENERGIZE (EPD Reset) button
located on the right side of the truck.
2-5.6. Parking
1. When finished moving loads, drive vehicle to its
maintenance or storage area.
2. To park, lift your foot from the brake pedal. This
deactivates the electrical circuits and engages the
mechanical brake.
3. Turn off the key switch.
4. Charge battery as required, see SECTION 3.
2-5.7. Battery Charging
Refer to Document 245 for battery safety and mainte-
nance.
NOTE: Battery charging instructions are contained in
SECTION 3.
2-6
2-5.8. Load Handling.
Proceed as follows to pick up or move a load on stock
selector lift trucks equipped with forks:
1. Before moving vehicle, lower the lift carriage.
NOTE: Lowering the lift carriage lowers the vehicle
center of gravity, which in turn increases the
stability when traveling.
2. Move the lift vehicle to the pick-up area.
3. Raise forks to the desired height for entry into the
pallet or skid.
4. Move into position, so that the forks are within the
pallet or skid and the load is centered over the
forks.
5. Move the vehicle to place load against edge of
operator deck; then raise forks to lift the pallet.
CAUTION: Avoid spilling the load. Move slowly and
use extra care when turning.
6. Slowly move the vehicle to free the load from its
rack; then when load is clear of its rack, lower the
load leaving enough floor clearance to maneuver.
7. Drive carefully to area where the load is to be
placed.
8. Move vehicle to align load with its new position.
9. Raise loaded forks to the height desired and
slowly drive into position.
CAUTION: The load must rest squarely on its rack
when it is lowered into position.
10. When the load is in position, lower the forks until
the pallet rests on its rack and the forks are free.
11. Move backwards slowly, making sure that the
forks do not catch on the pallet and lower the
forks when they are clear.
2-5.9. Pallet Clamp (Figure 2-3)
The pallet clamp is operated by the pallet clamp
release lever (12). Raise the release lever to close the
clamp on the center strings of the pallet being moved.
The extension spring accommodates the clamp to
varying board widths.
Lower the release lever to release the clamp; the
spring loading of the clamp then returns the clamp
arms to their idle position.
2-5.10.Moving a Disabled Truck
Do not attempt to move a disabled truck. Notify your
supervisor or proper authority.
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

3-3.2. Battery Servicing.
Refer to Document 245 for battery safety and mainte-
nance.
Perform the following procedures at end of each day:
1. Obtain a battery hydrometer.
NOTE: These can be obtained from a local hardware
store or automotive shop.
2. Open the battery cover and remove the vent caps.
3. Use the hydrometer to check specific gravity of
each cell.
NOTE: Battery specific gravity readings should agree
within ±0.025 from cell to cell. If variation is
greater, the battery may have to be repaired
or replaced.
CAUTION: Be sure that no cell plates are exposed
(not covered by fluid) before charging.
Add distilled water sufficient to just cover
top of cell places.
3-2
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)
No. 1 Transmission oil—EP SAE 80W-90 (in
temperatures below 32°F use 10W-30)
Transmission oil capacity is 3 pints.
No. 2 Grease—Lithium base, general purpose.
No. 3 Hydraulic oil-Heavy duty with a viscosity of
150 SUS (in temperatures below 32°F
use 100 SUS) foam suppressing agent
and rust and oxidation inhibitors.
Big Joe Part No.900855 (1 gallon)
900893 (1 quart)
No. 4 SAE 30 or 40 Engine lubricating oil
3-5. LIFT CHAIN MAINTENANCE.
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.
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
TROUBLE WITH LIFTING OR LOWERING
Platform does not lift to top.
Vehicle runs in forward and in
reverse, but platform does not
raise.
Vehicle runs and platform rises,
but will not go down.
Platform creeps downward
under load when in raised posi-
tion. Everything else is normal.
Squealing sounds from pump
when platform is raised.
Miscellaneous
Oil sprays or flows from the top
of the lift cylinder.
Oil foaming in breather of
hydraulic reservoir.
Oil splashes out of breather
when lowering platform.
4-2
PROBABLE CAUSE
a. Oil level too low.
b. Load heavier than capacity.
c. Defective pump or motor.
a. Defective electrical system.
b. Defect in hydraulic system.
a. Control valve defective or defect in
hydraulic system.
b. Defective hangup valve.
Leak in hydraulic system.
a. Oil level too low.
b. Dry channels in mast.
c. Defective bearing.
d. Pinched suction or plugged filter.
Defective packing in lift cylinder.
Leak in the suction line between the
pump and the reservoir.
Oil level too high.
CORRECTIVE ACTION
Check hydraulic oil level. Fill
hydraulic reservoir so that oil is
shown full on dipstick with the plat-
form fully lowered, before further
troubleshooting.
Refer to nameplate for maximum
load capacity.
Replace.
If pump does not run when lift push-
button is pressed, tighten electri-
cal connections. Check for
positive DC voltage at pump motor
to locate defect. Repair or replace
defective part.
Check for pinched hoses. Check
pump for proper operation.
Replace if necessary.
Check control valve for proper
action. Check for obstruction in the
hydraulic line. Repair as required.
Replace.
Look for loose fittings in the hydrau-
lic line. Check the check valve and
pump for leakage back into the
reservoir. Also check for overload-
ing or defective relief valve in
pump. Repair or replace as
required.
Check hydraulic oil level. Fill
hydraulic reservoir so that oil is
shown full on dipstick with the plat-
form fully lowered, before further
troubleshooting.
Apply grease.
Replace bearing.
Check lines and replace filter as
applicable.
Overhaul the lift cylinder and install
new packing and seal.
Tighten fittings. Inspect line and
replace if necessary.
Drain, then refill reservoir when lift
carriage is in the lowest position.
900980
4-2.1. Smooth Stepless Operation.
The Big Joe custom transistor controller allows supe-
rior operator control of the vehicle’s drive motor speed.
The amount of current delivered to the motor is set by
varying the “on” time (duty cycle) of the controller’s
transistors.This technique, called “pulse width modula-
tion” (PWM), permits silent, stepless operation.
4-2.2. Current Multiplication.
During acceleration and during reduced speed opera-
tion, the controller allows more current to flow into the
motor than flows out of the battery. The controller acts
like a DC transformer, taking in low current and high
voltage (the full battery voltage) and putting out high
current and low voltage. The battery only has to supply
a fraction of the current that would be required by a
conventional controller (in which the battery current
and motor current are always equal). The current mul-
tiplication feature gives vehicles using these control-
lers dramatically greater driving range per battery
charge.
4-2.3. Acceleration Limiting.
A built-in acceleration limiting circuit maintains a maxi-
mum rate of power increase to the motor. If full throttle
is applied at start-up, the acceleration ramp setting
determines how quickly the output of the controller
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
one second to reach full output. This feature contrib-
utes to a smooth, gentle start. (See adjustment
instructions to adjust acceleration ramp setting.)
4-2.4. Current Limiting.
The transistor controllers limit the motor current to a
preset maximum. This feature protects the controller
from damage that might result if the current were lim-
ited only by the motor demand. The current limit fea-
ture also protects the rest of the system. By eliminating
high current surges during vehicle acceleration, the
stresses on the motor and batteries are reduced and
their efficiency and service life are improved. Similarly,
there is less wear and tear on the vehicle drive train.
4-2.5. Plugging.
A form of electrical braking called plugging can be
used to slow the vehicle. When the motor is reversed
with the accelerator advanced (i.e., when the vehicle is
moving), the armature acts as a generator. Current
from the armature flows through a plug diode in the
controller. The controller regulates the current in the
motor field winding to give an appropriate level of plug-
ging torque. The vehicle slows smoothly to a stop,
then automatically accelerates in the other direction. A
tone may be heard during plugging. The maximum
plugging current is factory set and is field adjustable
(see adjustment instructions).
4-3
4-2.6. Undervoltage Protection
The control circuitry requires a minimum battery volt-
age to function properly. The controller is therefore
designed so its output is gradually reduced if the bat-
tery voltage fails below a certain level; the cutoff volt-
age for this model is listed in the specifications (see
Table 4-2). Reducing the output to the motor allows
the battery voltage to recover, and an equilibrium is
established in which the battery supplies as much cur-
rent as it can without failing below the cutoff voltage.
Table 4-2 Controller Specification
Big Joe Model 005467-02
Input Voltage 24-36
Current Limit 400 Amps*
Rating:
2 Minute 300 Amps
5 Minute 210 Amps
1 Hour 135 Amps
Voltage Drop @ 100 Amps 0.25 V
Under-voltage Cutback 13 V
Max F/R+1A Current 2 Amps
Operating Frequency 15 kHz
Standby Current <20 mA
Standard Throttle Input 0-5000 ohms.
±10%
* 30 Second rating.
4-2.7. Overvoltage Protection.
Similarly, the controller has a means of preventing
operation when battery voltage is too high for proper
functioning. Excess voltage can occur from an unregu-
lated battery charger or from improper or faulty wiring.
4-2.8. Thermal Protection.
Because they are well designed thermally, the control-
lers barely get warm in normal operation. If the internal
temperature of the controller exceeds 165°F, the cur-
rent limit drops off steadily until it is reduced to zero at
200°F. This allows the vehicle to be operated at a
reduced performance level in order to permit maneu-
vering out of the way and stopping in a good place.
After the controller cools down, full current and perfor-
mance return automatically. The controller shifts fre-
quency during overtemperature from its normal 15 kHz
to 1 kHz, providing an audible tone alerting the opera-
tor to the overtemperature condition.
The controller is also protected from undertempera-
ture. Should its internal temperature fall below -13°F (-
25°C) from being parked overnight in an icehouse, for
example, the current limit will be 1/3 the maximum.
Once the controller warms above -13°F (-25°C) full
current limit and performance return automatically.
4-2.9. Accelerator Fault Protection (Runaway Pro-
tection).
To prevent uncontrolled operation, the controllers shut
off the motor output in the event of a short circuit fault
in the accelerator or its wiring. The throttle configura-
tion is a 2-wire potentiometer ranging from 5000 ohms
for full off to 0 ohms for full on. The controller returns to
normal operation when the fault (e.g., accelerator wir-
ing, broken connectors, potentiometers that fail) has
been corrected.
4-2.10.Controller Fault Protection.
Faults can be caused internally (e.g., shorted transis-
tors) or externally (e.g., wrench or hardware dropped
across controller terminals). While disabled, the con-
troller's direction contactor output and internal logic
are both off.
Faults are detected by monitoring the controller's M-
output. If M-remains low for more than 20 ms, a fault is
detected. Fault protection is disabled for throttle
demand greater than 80%.
To recover from a fault, the F/R switch must be turned
off and back on again. If the fault has been corrected,
the controller will turn back on.
4-2.11. Weather Resistance.
All controllers are housed in rugged epoxy-sealed,
anodized aluminum extrusions that provide excellent
environmental protection.
4-2.12.Arcless F/R Switching.
Each time the F/R switch passes through neutral, the
controller's output is rapidly turned off (even if the
throttle is held on) so that all motor current has
stopped by the time the direction contactor drops out.
Controller output always starts at zero and increases
smoothly at the set acceleration rate each time a new
direction is selected.
4-2.13.High Pedal Disable (HPD).
When the controller Key Switch Input (KSI) is turned
on, it will sense a “high” (advanced accelerator) and
will inhibit the output until the accelerator is released
and reapplied. By preventing the unit KSI from being
turned on with the throttle depressed, this safety fea-
ture (also called Neutral Start) requires the truck to
start smoothly from zero throttle when the battery is
plugged in. It also protects against sudden starts
caused when problems in the throttle linkage

4-4 900980
(e.g., bent parts, broken return spring) give a partial or
full throttle signal to the controller even with the accel-
erator released when the battery is plugged in.
4-3. Controller Troubleshooting
4-3.1. Tools Required
Metric Wrenches for Contactors
Standard Wrenches
1/8 inch Allen Wrench
Insulated Screwdrivers
Analog Volt-ohmmeter
Clamp on DC Ammeter or Shunt Ammeter Setup
4-3.2. Procedure
The following procedures are to fix vehicles that don't
operate properly. Refer to the basic wiring schematic
(Figure 4-8 or Figure 4-9) when conducting these
tests. Make sure the controller is hooked up as shown
in Figure 4-8 or Figure 4-9. Refer to the wiring diagram
and schematic for your vehicle. These tests require a
general purpose volt-ohmmeter; you can use either a
conventional “V-O-M” or an inexpensive digital voltme-
ter.
In general, when a problem has been isolated to the
controller, remove and replace it. If the source of the
problem has not been determined or is suspected to
be within the truck (not the controller), proceed as
directed.
NOTE: Working on electric vehicles poses some
dangers. You must protect yourself against
runaways, high current arcs, and outgassing
from lead acid batteries:
Runaways — Some fault conditions could
cause the vehicle to run out of control. We
suggest that you jack up the vehicle and get
the drive wheels off the ground before
attempting these procedures or any other
work on the motor control circuitry.
High current arcs — Electric vehicle batter-
ies can supply very high power for short
times. If they are accidentally short circuited,
arcs can occur. Always open the battery cir-
cuit before doing work on the motor control
circuit. Wear safety glasses and use properly
insulated wrenches to prevent accidental
shorts.
Lead acid batteries — Charging or discharg-
ing batteries generates hydrogen gas, which
900980
can build up in and around the batteries.
Always follow the battery manufacturer's rec-
ommendations when working around batter-
ies. Wear safety glasses.
4-3.3. Check for Power to the Controller.
1. Leave the keyswitch off for these tests (if truck is
so equipped).
2. Verify that battery (-) connects to the B-terminal of
the controller, Figure 4-1. Connect voltmeter (-)
lead to this point.
3. Connect voltmeter (+) to the battery side of the
power fuse. Check for full battery voltage. If it is
not there, the trouble is in the battery pack or the
cables to it.
4. Connect the voltmeter (+) lead to the controller B+
terminal. You should read full battery voltage. If
this voltage is zero or close to zero, the trouble is
either a bad controller, a bad power fuse, or an
incorrectly connected cable. Trace the cable to
make sure it is hooked up right. If these check
out, the controller is malfunctioning.
4-3.4. Check for Contactor Operation and Key-
switch Input (KSI).
1. Turn the key on and depress brake pedal to
bypass deadman switch and release brake. Move
the accelerator in forward or reverse, until the
microswitch operates.
2. This should cause the forward or reverse contac-
tor to operate with an audible click. Connect the
voltmeter across the contactor coil terminal. You
should see full battery voltage.
3. The controller KSI terminal (top push on) (see Fig-
ure 4-1) should also be getting full battery voltage.
Verify this with the voltmeter. Connect the voltme-
ter (-) to the controller B-terminal, and the voltme-
ter (+) to the controller's KSI terminal.
4. If the contactor and KSI terminal are not getting
voltage, that's the problem. Use the voltmeter to
find out where it is not getting through. Connect
the voltmeter (-) to the controller's B-terminal and
check the following points with the voltmeter (+)
lead to trace the flow:
a. First, check both sides of the control wiring
fuse.
b. Check both sides of the keyswitch (if truck is
so equipped).
c. Check both sides of the accelerator
microswitch.
4-5
 d. Finally, check the contactor coil and controller
KSI.
5. If the contactor coil and KSI are getting voltage,
make sure that the contactor is really working, by
connecting the voltmeter across its big terminals.
There should be no measurable voltage drop. If
you see any at all, the contactor is bad.
4-3.5. Check Potentiometer Circuitry.
The following procedure applies to the basic accelera-
tor input configuration for these controllers, which is a
nominal 5000 ohm potentiometer connected as a two-
wire rheostat (0 ohms = full on, 5000 ohms = full off).
Some controllers are sold with other input characteris-
tics. If your installation used one of these optional
inputs, find out what its range is and use a procedure
comparable to the following to make sure your accel-
erator is working correctly.
1. With the forks lowered, the keyswitch off, and the
battery disconnected, pull off the connectors
going to the accelerator inputs of the controller.
(See Figure 4-1). Connect an ohmmeter to the
two wires and measure the resistance as you
move the accelerator. The resistance at the limits
should be within these ranges:
Accelerator at Start: 4300 ohms to 4800 ohms
Accelerator at Maximum: 0 ohms to 50 ohms
2. If these resistance's are wrong, it is because the
potentiometer itself is faulty or out of adjustment,
the wires to the pot are broken or disconnected,
the linkage is not moving the pot shaft through its
proper travel or a switch, resistor, or the relay is
defective or incorrectly wired. (See Figure 4-10 or
Figure 4-11 as applicable.)
3. While you have the accelerator wires off the con-
troller, use an ohmmeter to check for shorts
between these wires and the vehicle frame. You
should see a resistance of at least 10,000 ohms.
If it is lower than that, inspect the wiring for dam-
aged insulation or contact with the frame. If nec-
essary, replace the potentiometer.
4. Push the wires back on the controller terminals.
5. Inspect the terminal area of the controller closely.
Occasionally a build-up of dirt or acid residue of a
conductive nature may cause electrical leakage
between the accelerator input terminals and the
B- or M- terminals, leading to faulty accelerator
operation. To check for this problem, measure the
voltage at the lower pot terminal or at controller
(by connecting the voltmeter (-) lead to the con-
4-6
troller's B- terminal). The keyswitch must be on,
the brake pedal depressed (to bypass deadman
switch) and a directional switch engaged for this
test.
Lower Terminal
Accelerator at Start: 2.7 volts
Accelerator at Maximum: 7.0 volts
Compare your readings with these; if they are dif-
ferent by more than a few tenths of a volt, contam-
ination is probably the trouble.
6. Carefully clean off the terminal area of the control-
ler with a cotton swab or clean rag moistened with
water, and dry thoroughly. Now test the controller
to see if proper operation is restored. If so, you
should take steps to prevent this from happening
again. You must keep dirt and water from reach-
ing the terminal area of the controller.
4-3.6. Check for Controller Output.
1. Disconnect the wire from the direction contactors
to the F/R contactor output of the controller.
2. Connect the voltmeter (+) lead to the controller's
B+ terminal. Connect the voltmeter (-) lead to the
controller's M- terminal.
3. Connect the battery, turn on the keyswitch,
depress the brake pedal (to bypass deadman
switch), move the accelerator in forward, and
watch the voltmeter as you advance the accelera-
tor. The voltmeter should read zero with the accel-
erator released, and should read full battery
voltage with the accelerator at maximum. If it does
not, the controller is bad and must be replaced. If
the voltmeters readings are appropriate, release
the accelerator, turn off the keyswitch, disconnect
the battery, and reconnect the wire to the direction
contactors.
4. The next step is to measure the current in the
controller's M- lead. If you have a means of mea-
suring this high dc current, such as a shunt/meter
setup or a clamp-on dc ammeter, use it.
5. Connect the battery, turn the keyswitch on,
depress brake pedal (to bypass deadman switch),
move the accelerator in either forward or reverse,
and watch the ammeter while advancing the
accelerator.
6. If you see no current flowing in the M- lead, the
problem is an open circuit in the motor or the wir-
ing between the motor and the controller. Check
the F/R switch. Check contactors for reversing,
check to see that they are operating and that their
900980
 contacts are closing. If these are okay, check the
motor armature and field for opens.
7. If you do see a high current flowing in the M- lead,
but the motor does not turn, the problem is either
a short in the motor circuit, a miswired motor, or a
short in the controller's internal plug diode. Test
the plug diode as follows:
a. Remove power by opening the battery circuit.
Take the cable off the controller's A2 terminal.
b. Use an ohmmeter to check the resistance
between the controller's A2 and B+ terminals.
You are testing for the presence of a diode
inside the controller, so swap the two leads of
the ohmmeter and look for a low resistance
one way and a much higher one the other
way. If your meter has a diode test function,
use it.
c. If you find the diode to be shorted, the con-
troller is bad and needs to be replaced.
8. Put the A2 cable back on the controller.
9. If the plug diode is OK, there is a short in the
motor circuit. An ordinary ohmmeter will not work
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
rately if it is suspected of having a shorted wind-
ing.
10. Verify all illustrated connections and componentry
(Figure 4-10 or Figure 4-11) within the truck. If all
checks out and the source of the problem still has
not been found, replace the controller.
4-4. Adjustment of Controller Potentiometers
The controller has adjustable plug current, current
limit, and acceleration rate settings. The locations of
the adjustment pots are shown in Figure 4-2.
NOTE: Stop the truck and release the handle during
adjustment.
1. Remove the socket head screw (1/8” Allen) for
the adjustment you want to make.
2. Adjust the internal potentiometer with a small
insulated screwdriver, in order to provide the
desired performance for the identified characteris-
tics.
3. Replace socket head screw and nylon seal
washer. Tighten to 8 inch-pounds maximum to
prevent stripping.
4-7
4-5. EPD TROUBLESHOOTING
(Trucks Serial Number 356021 to 374092)
4-5.1. Emergency Power Disconnect Circuit Oper-
ation
The Emergency Power Disconnect (EPD) is designed
to remove operating power from the truck quickly in an
emergency. The circuit is shown in Figure 4-3. To
apply power to the lift truck the PUSH TO ENERGIZE
(EPD Reset) switch must be pressed momentarily. To
remove power quickly either the battery must be dis-
connected or the EPD switch must be pressed
momentarily. Circuit operation is as follows:
The negative side of the battery is connected to the
following three points.
1. One side of the EPD contactor coil which is deen-
ergized at this time.
2. One power contact on the de energized EPD con-
tactor.
3. One side of the EPD relay coil which is deener-
gized at this time.
The positive side of the battery is connected through
the 300 amp fuse then through the 15 Amp fuse to the
common contact on the PUSH TO ENERGIZE switch.
Initially both the EPD relay and the EPD contactor are
deenergized and the lift truck is inoperative.
When the PUSH TO ENERGIZE switch is pressed
momentarily the positive battery voltage is applied
through the switch to terminal A on the EPD relay.
Since terminal B is connected to the negative side of
the battery, the relay is energized and contacts 6 and 9
close. This completes a circuit from the 15 Amp fuse
through closed contacts 9 and 6 of the EPD relay to
the negative side of the battery and the contactor
energizes connecting battery voltage to the B-terminal
of the transistor controller where it is distributed to the
other truck electrical circuits.
A holding circuit must be provided to keep the EPD
relay and EPD contactor energized, otherwise when
the EPD Energize switch is released, these circuits
would deenergize again opening the EPD contactor
and deactivating the lift truck circuits. The EPD switch
provides this holding circuit. Note that when the EPD
relay contacts 9 and 6 close applying voltage to the
EPD contactor coil, this voltage is also applied to one
side of the EPD switch. The voltage passes through
the normally closed contacts of the EPD switch and is
applied to EPD relay terminal A. Now when the PUSH
TO ENERGIZE switch is released a complete circuit to
the EPD relay still exists keeping the relay energized.
This path is now from battery positive through the 300
4-8
Amp fuse, through the 15 Amp fuse, through EPD
relay contacts 9 and 6, through the closed EPD switch,
to terminal A on the EPD relay. This keeps the EPD
contactor energized maintaining battery negative to
the truck circuits.
When the EPD switch is pressed, the circuit to EPD
relay terminal A is opened and the EPD relay is deen-
ergized. EPD Relay contacts 9 and 6 open and
remove battery voltage from the EPD contactor, deen-
ergizing the contactor. With EPD relay contacts 9 and
6 open voltage is also removed from the EPD switch
circuit. Thus when the EPD switch is released the
EPD relay and contactor remain deenergized.
Pressing the EPD switch is the normal way of deener-
gizing the truck and setting the EPD to its initial condi-
tion with the EPD contactor open. Disconnecting the
battery will also causes the EPD circuit to be deener-
gized and returned to its initial state.
Remember that the EPD circuit is energized initially by
pressing the PUSH TO ENERGIZE switch momen-
tarily and is held in the activated state by the holding
circuit through the EPD switch.
4-5.2. Troubleshooting Procedure
Before trying to troubleshoot the EPD circuitry, read
the Emergency Power Disconnect Circuit Operation,
paragraph 4-5.1. Understanding the general overall
function and operation will simplify isolating faults.
The following troubleshooting information is based on
using a multimeter set to measure DC voltage on a
scale appropriate for measuring 24 VDC.
1. If the emergency Power Disconnect will not
engage, use the logic flow diagram, Figure 4-4, to
isolate the faulty component.
2. If the Emergency Power disconnect does not dis-
connect when the EPD switch is pressed, it will
usually be a short in the EPD switch circuit or a
faulty EPD relay.
3. If the EPD Contactor does not open when the bat-
tery is disconnected, the EPD contactor should be
replaced. You can check to see if the contactor is
open as follows:
a. Disconnect the battery from the truck.
b. Set multimeter to measure continuity (low
resistance)
c. Connect multimeter across the EPD contac-
tor contacts power (not the coil) and measure
the resistance. If resistance is near "0" resis-
tance, the contactor contacts are not open
and the contactor is faulty.
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-
ING (Trucks Serial Number 334374 to 374092)
The logic flow troubleshooting diagram provides a sim-
plified means of isolating the probable cause for a
problem by performing steps to obtain a "yes" or "no"
answer. Three types of blocks are used. Rectangular
boxes with a regular border provide procedural infor-
mation. Rectangular boxes with all upper case letters
identify a probable fault. Diamond shaped boxes ask
a question to obtain a yes or no answer. By following
the yes and no line the problem is identified.
CAUTION: Do not ever change the setting on the
potentiometer on the printed circuit
board. This is factory set to limit maxi-
mum output voltage. Incorrect setting of
this potentiometer can cause damage to
the charger or batteries.
CAUTION: A jumper is used on the printed circuit
logic board for part of the test. This
jumper must be installed with the
charger disconnected from the AC power
input.
Refer to Figure 4-5 for a complete schematic of the
charger. Figure 4-6 provides information for connect-
ing the jumper when necessary. Figure 4-7 is a logic
flow troubleshooting guide.

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

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.
5-5.1. Preliminary Preparation.
1. Place vehicle in an area that provides work space
on all sides.
2. Turn the drive wheel to a straight position.
3. Block wheels to prevent vehicle from rolling.
4. Raise carriage to a height of approximately six
feet to be able to work under it.
5. Place strong steel automotive-type supports
under the carriage approximately 24 inches out
from the mast.
6. Lower the carriage onto the supports using the lift
controls.
7. Check that the supports are secure and that the
carriage is lowered as far as it will go, but do not
allow slack in the lift chains.
8. Turn off the key switch and disconnect the battery
connector.
9. Remove the carriage access panel located below
the operator controls.
10. Remove the four screws securing the lower chas-
sis access door and remove the door.
5-5.2. Replacing Lower Steering Cable.
5-5.2.1.Trucks Serial Number 334774 to 354287.
NOTE: Top nut on each turnbuckle is right-hand
thread; bottom nut is left-hand thread.
1. Locate the steering cable turnbuckles on mast.
Loosen nuts (27 and 29, Figure 5-3) and turn
buckle (28) to relieve tension on the steering
cables. Separate the lower cable from buckle
(28).
2. Disconnect the steering cable at the steering
sheave by loosening two the nuts (27) and sliding
the steering cables out of its hole in sheave rim.
3. Remove the old steering cable from the vehicle.
4. Lay out old cable along the ground, measure it
and cut new cable to this length.
5. Attach the cable ends (26 and 30) to the cable.
Refer to paragraph 5-5.4.
6. Screw new lower cable assembly into buckle (28)
until the two parts are just threaded together.
7. Thread the lower end of the cable through the
sheaves (32).
900980
8. Wrap the new cable around the main steering
sheave to the hole from which the old cable was
removed.
9. Feed cable through its hole in the sheave and
install nuts (27).
10. Adjust the steering cable tension. Refer to para-
graph 5-2.
5-5.2.2.Trucks Serial Number 354287 to 374092.
NOTE: Top nut on turnbuckle is right-hand thread.
Bottom nut is left-hand thread.
1. Locate the steering cable turnbuckles on mast.
2. Loosen nuts (27 and 29, Figure 5-3 (sheet 3 of 3)
then separate the lower cables from the turnbuck-
les.
3. Disconnect the steering cables at the steering
sheave by loosening the jam nuts (36) then
loosening the screws (37) and (38).
4. Remove the old steering cable (30) from the
truck.
5. Screw the new lower cable assemblies into turn-
buckles (28) until the two parts are just threaded
together.
6. Thread the lower end of the cable through the
sheaves (32).
7. Wrap the new cable around the main steering
sheave 3/4 turn and insert the end of the cable
into the cable access hole.
8. Secure cable by tightening screws (37) and (38),
then secure screws with jam nuts (36).
9. Adjust the steering cable tension. Refer to para-
graph 5-2.
5-5.3. Replacing Upper Steering Cable.
NOTE: Top nut on each turnbuckle is right-hand
thread; bottom nut is left-hand thread.
1. Locate the steering cable turnbuckles on mast.
Loosen nuts (27 and 29, Figure 5-3) and turn
buckle (28) to relieve tension on the steering
cables. Separate the upper cable from buckle
(28).
2. Remove connecting link (19) to free the old cable
from chain (18).
3. Remove the old steering cable from the vehicle.
4. Lay out old cable along the ground, measure it
and cut new cable to this length.
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.
5-6.1. Removal.
1. Disconnect the battery.
2. Securely block load wheels.
3. Remove the four screws securing the lower chas-
sis access door and remove the door.
4. Make sure the four cables to the drive motor (1,
Figure 5-7 or Figure 5-8) are properly labeled A1,
A2, S1, and S2 and then disconnect the cables
from the drive motor.
5. Tag the two wires (26) attached to horn (29) and
disconnect the wires and spike suppressor (30).
Tag and disconnect the two wires (27) from dead-
man switch (28).
NOTE: Transmission oil capacity is 3 pints.
6. Remove the drain plug from transmission and
drain the oil.
7. Remove screw (22) and free barrel (16) from lever
(20).
8. Remove spring (11), cotter pin (9) and pin (13).
Move slave cylinder (15) out of the way.
9. Remove the carriage access panel located below
the operator controls.
NOTE: Top nut on turnbuckle is right-hand thread.
Bottom nut is left-hand thread.
10. Locate the steering cable turnbuckles on mast.
Loosen the nuts and turn the buckles to relieve
tension on lower steering cables.
11. Disconnect the steering cables as follows:
a. Trucks serial number 334774 to 354286,
remove two nuts (27, Figure 5-2, Sheet 2)
and remove cables (30) from the steering
sheave.
b. Trucks serial number 354287 to 374092,
remove two screws (37 and 38, Figure 5-2,
Sheet 3) and two nuts (36) and remove
cables (30) form the steering sheave.
12. Raise the truck off the drive wheel with jacks or
other suitable means. Place blocks under the
truck and remove the jacks.
13. Remove two cotter pins (14, Figure 5-4 or Figure
5-5) and two pins (10).
14. Support tube (7) with attached transmission and
remove two screws (1) and cap (2).
900980
15. Slowly lower pivot tube and transmission out of
truck chassis and remove ring (12), thrust bearing
(11), and two rings (15).
16. Remove the pivot tube as follows:
a. Trucks serial number 334774 to 354286,
remove four screws (57, Figure 5-7), lock
washers (58) and steering sheave (59) from
pivot tube (49). Remove four screws (50) and
pivot tube (49) from transmission (56).
b. Trucks serial number 354287 to 374092,
Remove four screws (57, Figure 5-8) and
four lock washers (58) and remove sheave
(50) and pivot tube (49) from transmission
(56).
5-6.2. Installation.
1. Attach pivot tube as follows:
a. Trucks serial number 334774 to 354286,
attach pivot tube (49, Figure 5-7) to transmis-
sion with four screws (50). Attach the steer-
ing sheave (59) with four screws (57) and
lock washers (58).
b. Trucks serial number 354287 and higher,
attach pivot tube (49, Figure 5-8) and steer-
ing sheave (50) to transmission with four
screws (57) and four washers (58).
2. Position the pivot tube and transmission assem-
bly under the truck chassis and carefully insert the
pivot tube up into the pivot tube weldment while
installing two rings (15, Figure 5-4 or Figure 5-5)
thrust bearing (11) and ring (12) on the tube.
3. Align the holes of rings (15) with the holes in tube
(7) and install pins (10) and cotter pins (14).
4. Position cap (2) on end of tube (7) and secure
with screws (1).
5. Remove the blocking and lower the vehicle to the
ground.
6. Connect lower steering cable as follows:
a. Trucks serial number 334774 to 354286,
reconnect the two steering cables (30, Figure
5-3, sheet 2) to the sheave and secure with
two nuts (27).
b. Trucks serial number 354287 to 374092,
reconnect the two lower steering cables (30,
Figure 5-3, Sheet 3) and secure with the two
screws (37 and 38) then lock down with jam
nuts (36).
7. Check that the steering cables are properly posi-
tioned on their sheaves.
5-11
8. Adjust the steering cable tension. Refer to para-
graph 5-2.
9. Position slave cylinder (15, Figure 5-7 or Figure 5-
8) in bracket (12) and install pin (13), cotter pin (9)
and spring (11).
10. Secure barrel (16) to lever (20) with screw (22).
NOTE: Transmission oil capacity is 3 pints.
11. Reinstall the transmission drain plug and fill the
transmission with oil to the proper level.
12. Reconnect the four cables to the drive motor (1).
13. Reconnect the two wires (26) and spike suppres-
sor (30) to horn (29). Reconnect the two wires
(27) to deadman switch (28).
14. Reconnect the battery.
15. Secure the lower chassis access door with the
four screws.
16. Remove the blocks from the load wheels.

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
The chassis mounted parts of the brake system are
shown in Figure 6-1 or Figure 6-2 and the carriage
mounted parts are shown in Figure 6-3.
6-2. BRAKE DEADMAN SWITCH
The brake deadman switch is mounted on the trans-
mission. Proceed as follows to check and adjust the
switch:
1. Remove the four screws securing the lower chas-
sis access door and remove the door.
2. With the brake pedal in the raised position, check
that the tab of lever (20, Figure 6-1 or Figure 6-2)
depresses the button of switch (28), but does not
touch the switch bushing.
3. If the tab of lever (20) does not depress the switch
button, loosen the switch mounting bolts and
move switch (28) toward lever (20), then tighten
the mounting bolts.
4. If the tab of lever (20) depresses the switch button
and also touches the switch bushing, loosen the
switch mounting screws and move the switch
slightly away from lever (20), then tighten the
mounting bolts.
5. Check actuation of brake deadman switch by lis-
tening for the audible click as the brake pedal is
depressed and again as the brake pedal is
released.
6. Secure the lower chassis access door with the
four screws.
6-3. BLEEDING THE BRAKE SYSTEM
1. Remove the carriage access panel located below
the operator controls.
2. Remove the four screws securing the lower chas-
sis access door and remove the door.
3. Set the pressure bleeder at approximately 20 PSI.
4. Attach the bleeder hose connector to the reservoir
(1, Figure 6-3).
5. Open the bleeder screws at both actuator (3) and
slave cylinder (15, Figure 6-1 or Figure 6-2).
6. Open the bleeder screw on the pressure bleeder.
900980
7. When all air has been removed and clear system
fluid is observed, close the actuator bleeder and
then the slave cylinder bleeder.
8. Close the pressure bleeder valve and remove the
bleeder from the reservoir.
NOTE: Use hydraulic oil only in brake system.
9. Refill reservoir as needed. Do not allow reservoir
to completely empty.
10. Install the carriage access panel below the opera-
tor controls.
11. Secure the lower chassis access door with the
four screws.
6-4. BRAKE HOSE REPLACEMENT
The brake hose is adjusted by loosening the brake
hose clamps, taking the slack out of the hose then
retightening the hose clamps
6-5. BRAKE ADJUSTMENT
1. Block the load wheels to prevent the vehicle from
moving.
2. Turn off the key switch and disconnect the battery
connector.
3. Remove the four screws securing the lower chas-
sis access door and remove the door.
4. Jack up the vehicle so drive wheel (53, Figure 6-1
or Figure 6-2) is off the ground and securely block
the vehicle.
5. When the brake pedal is released, (UP), the
brake should grab firmly enough so the disc (3)
cannot be turned by hand. Tighten nut (8) to
increase braking force.
6. Depress the brake pedal. If the brake does not
fully release disc (3), remove shoulder bolt (22)
and partially unscrew brake barrel (16) out on
slave cylinder rod. Reconnect linkage and test
again.
7. If additional adjustment is necessary or if the
brake pedal (5, Figure 6-3) cannot travel to the
floor, loosen the jam nut on actuator (3) and turn
rod to increase or decrease pedal height.
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
and 48). Also discard any other parts that are
worn or damaged. Replace parts with new.
11. Assemble washer (47). lever (46), bracket (38),
spring (45), washer (44), and C-ring (43) to the
brake pad (48).
12. Assemble brake pad (41), springs (40), and spac-
ers (39) to the two bolts (42).
13. Slip the parts assembled in step 11. onto bracket
(7) and hold them so the bolt holes are aligned.
900980
14. Insert bolts (42) through pad (48) and bracket
(38), so the threaded portion of the bolts pass
completely through.
15. Assemble lock washer (37) and nuts (36) on bolts
(42).
16. Engage clevis (18) with the lever (46), then
secure with cotter pin (9).
17. Reassemble clevis pin (17), cotter pin (19), spring
(11), rod (10), lockwasher (33) and jam nut (8).
18. Adjust the brake. Refer to paragraph 6-5.
6-5
 NOTES

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

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

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
1. Secure drive motor (38, Figure 7-3) to transmis-
sion (31) with two screws (24) and washers (18).
2. Position block (12, Figure 7-1 or Figure 7-2) on
transmission (56) and secure with lock washers
(33) and screws (32).
3. Position bracket (24) and horn (29) on transmis-
sion (56) and secure with lock washers (33) and
screws (31).
4. Position lever (20) in bracket (24) and install pivot
pin (23) and cotter pins (9).
5. Insert bushing (21) in lever (20). Connect clevis
(18) to lever (20) with clevis pin (17) and cotter pin
(19).
8. Install wheel (53) with the five hex head screws
(51) and lock washers (52).
9. Install the pivot tube (complete with transmission,
drive wheel and motor). Refer to SECTION 5.
10. Check brake adjustment. Refer to SECTION 6.
7-4. DRIVE WHEEL REPLACEMENT
1. Remove the pivot tube (complete with transmis-
sion, drive wheel and motor). Refer to SECTION
5.
2. Remove the five hex head screws (51, Figure 7-1
or Figure 7-2) and lock washers (52) that secure
the drive wheel (53) to the axle shaft and then
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.
Both lift chains should be replaced when either chain
is worn enough to increase it's length by 3% or more. 4.
To make their determination proceed as follows.
Using a section of chain that sees the most frequent
operation over the chain sheaves, isolate a vertical 5.
portion under tension from the weight of carriage and
forks. 6.
For chain part #402034: Measure the distance
between pin centers on 20 vertical links. If the section
measures 12.88" or more, the chain should be 7.
replaced.
New chain anchor pins should be installed when WARNING: Before attempting any actual replace-
chains are replaced. Never replace a partial section of
chain and never repair a damaged chain. Refer to
paragraph 8-5 when installing new chain.
8.
8-5. LIFT CHAIN REPLACEMENT
1. Place vehicle on level surface. 9.
2. Block wheels to prevent vehicle from rolling.
Raise carriage to a height of approximately three
feet.
Place strong steel automotive-type supports
under the carriage approximately 24 inches out
from the mast.
Lower the carriage onto the supports using the lift
controls.
Model SSCM 20-130 Telescopic: Place steel
blocks under the bottom edges of the inner mast
to support it solidly.
Check that the supports are secure and that the
carriage is lowered as far as it will go.
ment, make certain power is discon-
nected.
Turn off the key switch and disconnect the
battery connector.
Remove the cotter pin (17 Figure 8-1 or
Figure 8-2) and clevis pin (18) from end of chain
connected to mast cross brace.

8-4 900980
10. Remove the cotter pin (17) and clevis pin (17)
from end of chain connected to lift carriage.
11. Remove chain from sheave (9) and lay aside for
repair.
12. Position new chain in place on sheave.
13. Connect end of chain to lift carriage adjusting bolt
(19) with the clevis pin (18) and cotter pin (17).
14. Connect end of chain to chain anchor on mast
cross brace with the clevis pin (18) and cotter pin
(17).
15. Adjust lift chain. Refer to paragraph 8-3.
8-6. LIFT CYLINDER REPLACEMENT
1. Place vehicle in an area that provides work space
on all sides.
2. Block wheels to prevent vehicle from rolling.
3. Raise carriage to a height of approximately three
feet.
4. Place strong steel automotive-type supports
under the carriage approximately 24 inches out
from the mast.
5. Lower the carriage onto the supports using the lift
controls.
6. Model SSCM 20-130 Telescopic: Place steel
blocks under the bottom edges of the inner mast
to support it solidly.
7. Check that the supports are secure and that the
carriage is lowered as far as it will go.
8. Turn off the key switch and disconnect the
battery connector.
9. Chain the ram head (10, Figure 8-1 or Figure 8-2)
to the mast to support it during cylinder removal.
10. Place any container suitable for catching a few
pints of oil under elbow (12, Figure 8-1 or Figure
8-2).
11. Disconnect hose (19) and allow hose to drain into
container.
12. Disconnect overflow tube (6).
13. Remove screw (28, Figure 8-1 or Figure 8-2), lock
washer (15), and washer (29) from the bottom of
the lift cylinder.
WARNING: Keep fingers out of the way of the cylin-
der as it descends when free.
14. Remove screw (11) and lock washer (12).
15. Remove two nuts (14), two lock washers (15) and
clamp (16).
900980
CAUTION: The lift cylinder is very heavy.
16. Raise the lift cylinder (30) up and out of the mast.
17. Position the new or repaired lift cylinder in the
mast.
18. Reinstall clamp (16), two lock washers (15) and
two nuts (14).
19. Secure the bottom of the lift cylinder with screw
(28), lock washer (15), and washer (29).
20. Reconnect pressure hose (19, Figure 12-14) and
overflow tube (6) to the cylinder.
21. Refill hydraulic reservoir (4).
22. Reconnect battery, turn on key switch, and acti-
vate lift control to raise cylinder to ram head.
23. Secure top of lift cylinder ram head (10,
Figure 8-1 or Figure 8-2) with screw (11)
and lock washer (12).
24. Remove the chains securing the ram head to the
mast.
25. Raise the lift carriage and remove the supports.
26. Remove the blocks from the wheels.
8-7. LIFT CARRIAGE REMOVAL
1. Place vehicle on level surface.
2. Block wheels to prevent vehicle from rolling.
3. Raise carriage to a height of approximately three
feet.
4. Place strong steel automotive-type supports
under the carriage approximately 24 inches out
from the mast.
5. Lower the carriage onto the supports using the lift
controls.
6. Model SSCM 20-130 Telescopic: Place steel
blocks under the bottom edges of the inner mast
to support it solidly.
7. Check that the supports are secure and that the
carriage is lowered as far as it will go.
WARNING: Before attempting any actual replace-
ment, make certain power is discon-
nected.
8. Turn off the key switch and disconnect the
battery connector.
9. Remove two screws (2, Figure 8-1 or Figure 8-2)
and lock washers (1) from the top of the mast.
10. Remove the cotter pin (17) and clevis pin (18)
from end of chain connected to lift carriage.
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.
Primary components of the hydraulic system (Figure
9-1) are the reservoir, filter, pump, relief valve, lift cylin-
der, flow control valve, hangup valve, and manual
release valve. Depressing the lift pushbutton applies
battery voltage to the pump motor relay, energizing it
to start the pump motor. The pump then draws hydrau-
lic oil from the reservoir through the hangup valve and
flow control valve to the hydraulic lift cylinder. The
pump continues to function, and the cylinder lifts the
platform until the lift pushbutton is released or the plat-
form reaches its maximum height.
Depressing the lower pushbutton applies battery volt-
age to the solenoid valve on the pump. This permits
the hydraulic oil to flow back from the lift cylinder,
through the flow control, hangup valve, and solenoid
valve back into the reservoir, letting the platform
descend. The flow control valve is preset to the maxi-
mum desirable lowering speed. The hangup valve is a
safety device. This valve is operated by the hydraulic
pressure applied to it by the weight of the descending
platform. If the platform strikes an obstruction while
descending and hangs up on the obstruction, the
decrease in hydraulic pressure causes the valve to
close. This stops the downward motion of the cylinder
and mast, preventing the chains and cables from com-
ing loose. The relief valve is set to provide sufficient
hydraulic pressure to lift the rated load, but excessive
R3156
Figure 9-1 Hydraulic Schematic Drawing
900980
pressure causes the relief valve to open, and allows
the oil to flow back into the reservoir.
Trucks without the optional carriage operated manual
lowering system will have a release valve (43, Figure
9-2) located next to the pump motor. Components for
the standard hydraulic system are shown in Figure 9-
2. Components for the optional carriage operated
manual lowering system are shown in Figure 9-5.
9-2. RELIEVING SYSTEM PRESSURE.
WARNING: Hydraulic system pressure must be
relieved before removing hydraulic sys-
tem components. Use the following pro-
cedure to relieve system pressure:
1. Fully lower the lift carriage unless the procedure
for a component directs differently.
2. Disconnect battery.
CAUTION: Use rags and a suitable container to
catch any dripping oil when the hydraulic
lines are disconnected. Wipe off any
spilled oil immediately.
3. Obtain a suitable container to catch any oil that
may escape when opening a line.
4. Open the low pressure line at any convenient
connection near the component that is to be
repaired or replaced.
9-1
9-3. HYDRAULIC PRESSURE ADJUSTMENT.
WARNING: Improper setting of the hydraulic pres-
sure by an unauthorized person can void
your Big Joe guarantee.
The relief valve is factory set to open beyond the rated
capacity of the system and rarely needs adjusting. If
you suspect that the relief valve is malfunctioning, per-
form the following procedures:
CAUTION: A pressure gauge must be used.
1. Lower lift carriage as far as it will go.
2. Disconnect hose (20, Figure 9-2) at tee (21) and
connect a pressure gauge of adequate range (0-
3000 psi) to tee(21).
3. Activate pump motor until cylinder hits stop and
observe reading on pressure gauge. If pressure
reading is 1575 psi, the relief valve is functioning
properly and does not need adjustment. Deacti-
vate pump motor. Lower completely. Disconnect
gauge, and reconnect pressure hose. If pressure
reading is above or below 1575 psi, proceed to
adjust the relief valve as follows:
CAUTION: Do not set pressure too high or lift
assembly and hydraulic system may be
damaged.
4. Back off lock not of adjusting screw on relief valve
(39).
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.
NOTE: Leaking hydraulic fittings can sometimes be
remedied by simply tightening the fitting. If
this does not remedy the leak, the fitting or
line must be replaced. A leak in the suction
line between the pump and the reservoir will
sometimes cause hydraulic oil to foam
through the vent.
WARNING: Before disconnecting any hydraulic lines,
make certain the system is not under
pressure. Refer to paragraph 9-2..
1. Remove reservoir drain plug (49, Figure 9-2) and
drain hydraulic oil into a suitable container.
2. Remove the leaking line or fitting and replace it
with a new one. Refer to Figure 9-2.
3. Clean the drain plug thoroughly.
4. Reinstall the drain plug.
NOTE: Refill only with Big Joe hydraulic oil, and only
while the lift carriage is completely lowered.
Refill until oil is to the “FULL” mark on the dip
stick. Refer to Section 3 for oil capacities.
5. Remove the reservoir vent cap, fill the reservoir to
the “FULL” mark on the dip stick, and replace the
vent cap.
6. Reconnect battery.
7. Operate the hydraulic controls and check for
leaks.
9-5. SUMP FILTER REPLACEMENT.
1. Lower the lift carriage as far as it will go.
2. Turn off key switch and disconnect the battery
connector.
3. Open the upper compartment door.
NOTE: A small funnel with a few feet of 1/2 inch hose
will facilitate draining oil from the reservoir.
900980
4. Remove plug (49, Figure 9-2) and drain the
hydraulic oil from reservoir (4) into a clean bucket
or suitable container.
5. Loosen clamp (32) and disconnect suction hose
(33) from nipple (53).
6. Trucks serial number 334774 to 357009:
Remove nuts (52) and hold down plate (51).
7. Remove filter (50).
8. Trucks serial number 334774 to 357009:
Remove O-ring (7) from filter (50).
9. Clean or replace filter (50).
10. Trucks serial number 334774 to 357009: Install
new O-ring (7) on filter (50).
11. Reinstall filter (50).
12. Trucks serial number 334774 to 357009: Install
plate (51) with nuts (52).
13. Reattach hose (33) to nipple (53) with clamp (32).
14. Refill the hydraulic reservoir.
9-6. HANG-UP VALVE REPLACEMENT.
1. Lower the lift carriage as far as it will go.
2. Turn off key switch and disconnect the battery
connector.
3. Open the upper compartment door.
NOTE: A small funnel with a few feet of 1/2 inch
hose will facilitate draining oil from the reser-
voir.
4. Remove plug (49, Figure 9-2) and drain the
hydraulic oil from reservoir (4) into a clean bucket
or suitable container.
5. Disconnect hose (19) at elbow (12) at valve (13).
6. Remove elbow (12) from valve (13).
7. Remove valve (13) from nipple (18) and install
new valve with arrow pointing toward elbow (12).
8. Reinstall elbow (12) and reconnect hose (19).
9. Refill the hydraulic reservoir.
9-3
9-7. HYDRAULIC PUMP AND MOTOR ASSEMBLY.
The hydraulic pump and motor assembly can be
replaced as a unit. Portions of the hydraulic pump and
motor assembly may be repaired. A new set of
brushes may be installed in the motor or the motor can
be rebuilt. However, a defective pump has to be
replaced as a complete unit. If the hydraulic pump and
motor is disassembled, the gasket (3, Figure 9-3) must
be replaced.
1. Lower the lift carriage as far as it will go.
2. Turn off key switch and disconnect the battery
connector.
3. Open the upper compartment door.
NOTE: A small funnel with a few feet of 1/2 inch hose
will facilitate draining oil from the reservoir.
4. Remove plug (49, Figure 9-2) and drain the
hydraulic oil from reservoir (4) into a clean bucket
or suitable container.
5. Tag and disconnect the electrical leads from the
pump and motor assembly.
R3125
Figure 9-3 Hydraulic Pump and Motor Assembly
9-4
WARNING: Before disconnecting any hydraulic lines,
make sure the system is not under pres-
sure.
6. Disconnect hose (19 and 32) at the pump.
7. Remove hose (26) from the pump.
8. Remove the four nuts (56) and four washers (28)
and remove the pump and motor assembly from
the vehicle.
9. Remove the two screws (29) and two washers
(28) and remove plate (30) from the pump and
motor assembly.
10. If the pump and motor assembly or the pump are
to be replaced, remove the fittings from the pump
and reinstall in the new assembly.
11. If the pump and motor are to be separated, refer
to Figure 9-3.
12. If the motor is to be disassembled, refer Section
10.
13. Reassemble and reinstall in vehicle by reversing
the sequence of the disassembly procedure.
900980
 NOTES

900980 9-5
9-8. LIFT CYLINDER REPAIR.
CAUTION: Use proper pipe clamp type vise to
secure the cylinder. The cylinder will be
distorted if the vise is tightened too
much.
1. Secure lift cylinder in a vise and remove gland nut
(3, Figure 9-4) from cylinder tube (1).
2. Remove O-ring (4) and wiper ring (2) from gland
nut (3).
3. Pull cylinder rod (5) out of tube (1).
NOTE: Cylinders equipped with piston (8), install ret-
rofit kit 907122.
NOTE: Cylinders equipped with piston (14), install
packing kit 907121.
9. Inspect piston (8), rod (5), jackstop (6), and gland
nut (3) for scores, cracks, or deep scratches.
10. Coat seal (15) and piston (14) liberally with petro-
leum jelly. Install new seal (15) on piston (14).
11. Install new O-ring (7), piston (14) and nut (11)
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)
and, while compressing spring, tighten screws on
clamp (4). When released, spring should pull
cable taut.
6. If spring and clamp do not move, cable was pulled
too taut; if spring expands fully, slack was not
removed. Repeat steps 3. through 5. if necessary.
7. Remove blocks and lower lift carriage.
10-2.2.Replacement.
1. Move the vehicle to an area suitable for the repair
operation.
2. Block the wheels to prevent the vehicle from mov-
ing.
3. Raise the carriage to a height of three to six feet
to be able to work under it.
4. Place strong automotive supports under the car-
riage approximately 24 inches out from the mast.
5. Lower the carriage onto the supports.
6. Check that the supports are secure and that the
carriage is lower as far as it will go.
7. Turn off the key switch and disconnect the
battery connector.
8. Remove the carriage access panel located below
the operator controls.
9. Cut cable wires at terminal board (23, Figure
10-4) leaving sufficient wire to identify wire color
code.
10. Free the cable from strain relief (36) and pull the
cable out of the cable guide.
11. Lift the cable from over the ram head sheave and
lower to ground.
12. Open the upper access door.
13. Cut the cable wires at electrical panel (33, Figure
10-5 or Figure 10-6) leaving sufficient wire to
identify wire color code.
14. Cut the cable wires at connector (28) leaving suffi-
cient wire to identify wire color code.
15. Remove clamps securing cable inside compart-
ment.
16. Pull the old cable out of the compartment.
17. Remove zipper tubing (26) from the cable.
18. Lay out old cable along the ground, measure it
and cut new cable to this length, allowing several
extra inches to facilitate fitting and to account on
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.
20. Strip off the outer sheathing of the cable.
NOTE: The color coding on the short piece of wire
cut from the old cable can be used to insure
proper connection of the new cable.
21. Connect the cable to terminal board (23, Figure
10-4) as follows: Match the color of the new cable
wires with the short piece of wire cut from the old
cable. Cut each cable wire to proper length, strip
its end and crimp new terminals to wire ends.
Remove the short piece of wire from the old cable
and replace with the same color wire of the new
cable.
22. Route the length of cable over its sheave on the
ram head and down into the compartment.
23. Install the zipper tube over the cable and secure
the cable with the clamps previously removed.
24. Strip off the outer sheathing of the cable.
NOTE: The color coding on the short piece of wire
cut from the old cable can be used to insure
proper connection of the new cable.
25. Connect the cable to electrical panel (33, Figure
10-5 or Figure 10-6) as follows: Match the color of
the new cable wires with the short piece of wire
cut from the old cable. Cut each cable wire to
proper length, strip its end and crimp new termi-
nals to wire ends. Remove the short piece of wire
from the old cable and replace with the same
color wire of the new cable.
26. Connect cable to connector (28) in the same
manner.
27. Secure the cable in strain relief (36, Figure 10-4)
28. Close the upper access door and install the car-
riage access panel.
10-4
29. Reconnect the battery connector to restore the
vehicle to normal service.
10-3.ELECTRICAL CONTROL PANEL.
10-3.1.Adjustment of Controller Potentiometers.
The controller has adjustable plug current, current
limit, and acceleration rate settings. Refer to SEC-
TION 4.
10-3.2.Panel Replacement.
1. Turn off the key switch and disconnect the battery
connector.
2. Open the upper access door.
3. Tag and disconnect all electrical wires and cables
from electrical panel (33, Figure 10-5 or Figure
10-6).
4. Remove two nuts (34), lock washers (35), and flat
washers (36) and remove the electrical panel
(33).
5. Install the electrical panel assembly in reverse
order.
10-3.3.Panel Disassembly and Reassembly.
1. Refer to Figure 10-7 for identity of components of
the electrical panel, and remove defective compo-
nents as required.
2. Be sure to make note of the location of bussbars
(13), when removing contactors (5), to facilitate
reassembly.
3. Upon reassembly of the electrical panel, inspect
each electrical connection to ensure that a good
positive contact is made at all wire and cable con-
nections.
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.
1. Remove spring stud (3, Figure 10-8) and spring
(4).
2. Remove nut (31), lock washer (30), washer (29),
bolt (27), and bus bar (1) (if used).3. Slide back
contact (2) up as far as possible then squeeze
sides of rear molding (28) together and lift off of
frame (19). Separate two sides of rear molding
and remove back contact (2).
3. Remove nut (26) and remove retainer (25) by
squeezing in on tabs and lifting up.
4. Slide braid assembly (24) off contact (5) and
remove contact (5) and armature plate (6) and
spring (4).
5. Remove nut (12), lock washer (11), flat washer
(10) and contact (13).
NOTE: If only the contacts are to be replaced, no fur-
ther disassembly is required. Proceed to step
5 to replace coil.
6. Remove spacer (14).
7. Squeeze sides of front molding (15) and pull for-
ward to disengage from base molding (16).
Remove base molding and remove front molding
from frame (19).
8. Coil (8) can now be removed from frame (19) by
removing the screw (17) and flat washer (18).

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.
1. Place the bolt (9, Figure 10-8) through bottom of
front molding (15) and slide molding onto frame
(19).
2. Attach coil (8) to frame (19) with flat washer (18)
and screw (17). Be sure braid assembly (24) has
been attached to frame (19) with the bolt (20), flat
washer (21), lock washer (22) and nut (23).
3. Attach frame (19) to base molding (16) by engag-
ing slots at bottom of frame (19) behind flanges
near lower edge of base molding (16).
4. Snap slots at top of front molding (15) into flanges
of base (16). Coil (8) should now be securely
attached to base (16).
5. Install spacer (14) on molding (15) and install front
contact (13) with washer (10), lock washer (11)
and nut (12).
6. Place contactor on work surface with base mold-
ing (16) down. Place spring (4) on center of pole
piece (7).
7. Position armature plate (6) against frame (19).
8. Place moving contact assembly (5) on armature
plate (6). Then attach braid assembly (24) to con-
tact stud.
9. Place retainer (25) over contact stud and slip the
two tabs on retainer (25) into the two slots in
armature plate (6). Secure with hex nut (26).
10. Place two parts of rear molding (28) together and
slide back contact (2) into slot in molding.
11. Squeeze back molding (28) together and place
grooves in back molding on frame (19). Push
molding all the way down.
12. Release back molding (28) and press contact (2)
down into position. Armature (6) will need to be
pressed down to position contact (2).
13. Reattach bus bar (1) to contact (2) with bolt (27),
washer (29), lock washer (30) and nut (31).
14. Secure moving contact (5) to armature (6) with
spring (4) and spring stud (3).
10-4.PUMP MOTORS.
Two different pump motor assemblies have been used
on the SSCM Truck. Pump motor 905046 is used on
trucks serial number 334774 to 342086. Pump
10-10
motor 901547 is installed as original equipment on
trucks serial number 342087 to 374092.
NOTE: Removal procedures are covered in SEC-
TION 8.
Refer to applicable Figure 12-24, Figure 12-25 or Fig-
ure 12-26 for motor disassembly.
10-5.DRIVE MOTORS.
NOTE: Removal procedures are covered in SEC-
TION 6.
Refer to Figure 12-27 for motor disassembly.
10-6.BATTERIES.
NOTE: Batteries are heavy. Use care when lifting out
of battery compartment.
1. Turn off the key switch and disconnect the battery
connector.
2. Disconnect the battery cables from the battery ter-
minals.
3. Lift the battery out of the battery compartment.
4. Lower the new battery in the battery compart-
ment.
5. Reconnect the battery cables to the battery termi-
nals.
6. Reconnect the battery connector.
10-7.HIGH SPEED LIMIT SWITCH.
10-7.1.Operational Check
Perform this operational check to be sure that the high
speed limit switch is operating properly:
1. Position the lift carriage so that it is higher then 24
inches above the floor.
2. Drive at a moderate speed and then twist the
directional switch to full speed. The rate of travel
should not increase to top speed.
3. Stop and lower the lift carriage so that it is less
then 24 inches above the floor.
4. Drive at a moderate speed and then twist the
directional switch to full speed. The rate of travel
should increase to top speed.
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.
FOR TRUCKS SERIAL NUMBER 334774 TO
356020 SEE SUPPLEMENT 326 FOR EPD
CONTACTOR RETROFIT KIT 31366
10-9.1.Assembly Replacement (Trucks serial num-
ber 356021 to 374092).
1. Turn off the key switch and disconnect the battery.
2. Remove the lower access door (16, Figure 12-8).
3. Tag and disconnect all electrical wires and cables
from the EPD contactor assembly.
4. Remove the two nuts (3, Figure 10-6), two lock-
washers (4), two flat washers(5) and spacer (6).
and remove the EPD assembly
10-9.2.EPD Contactor Assembly - (Assembly/Dis-
assembly)
1. Refer to Figure 10-9 for illustration of components
of the EPD contactor assembly, and remove
defective components as required.
2. Upon reassembly of the EPD contactor assembly,
inspect each electrical connection to ensure that a
good positive contact is made at all wire and
cable connections.
10-10.EPD Contactor Repair
1. Refer to Figure 10-10 for illustration of compo-
nents included in the contactor repair kit, part
number 906000.
2. Remove washer (1), spring (2), bridge 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