~.•.

Manual 901353
Model PDM S/N 333620 and Higher

This manual is affected by the following BULLETINS:

These are found in the bulletin folder of the navigation screen.

Bulletin Rev Title

187 Transistor Speed Controller
207 Transistor Control Head
220 A Transistor Control Head
228 Trans Controller/Contactor pan
(Type E Trucks)
245 Battery Safety and Maintenance
272 Battery Quick Disconnect Cable kits
318 Control Arm Assembly
325 PDM Adjustable Straddle Supplement
329 A Speed Resistor Retrofit
330 PDM Smart Charger 004983-01
333 PDM Pump & Motor 016939
342 PDM Wai-Mart Truck
356 Cylinder 503568 packing change
364 Alltrax 12V Controller 005467-03

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 Manual Price $35.00

PDM SERIES
POWER DRIVEN
MEDIUM DUTY
LIFT TRUCK
Serial Number 333620 and Higher
Operation
Maintenance
Repair Parts List

Big Joe Manufacturing Company-Lincolnwood, IL 60646 MANUAL NO. 901353

02/09/2015

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 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, hom, lights, battery, controller, lift system (including forks or attachments, chains,
cables and limit switches), brakes, steering mechanism, guard and safety device.
Operate truck only from designated operating position. Never place any part of your body
into the mast structure or between the mast and the truck. Do not carry passengers. Keep
feet clear of truck.
Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and
sound hom 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.
Use special care when operating on ramps- travel slowly, and do not angle or turn. Travel
with lifting mechanism downhill.
Do not overload truck. Check capacity plate for load weight and load center information.
When using forks, space forks as far apart as load will permit. Before lifting, be sure load
is centered, forks are completely under load, and load is as far back as possible against
load backrest.
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 handle loads which are higher than the load backrest or load backrest extension
unless load is secured so that no part of it could fall backward.
Elevate forks of 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. Never transport
personnel on forks or work platform.
Do not allow anyone to stand or pass under load or lifting mechanism.
When leaving truck, neutralize travel control, fully lower lifting mechanism and set brake.
When leaving truck unattended, also shut off power.

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• Section
1 DESCRIPTION
1-1
1-2
TABLE OF CONTENTS

Introduction ................
General Description .........
Page

1-1
1-1
Section
6 BRAKE
6-1
6-2
SERVICING
General ..................
Adjustment. ...............
Page

6-1
6-1
1-3 Safety Features ............. 1-1 6-2.1 Adjustment for Truck Serial .... 6-1
1-4 Options and Accessories ...... 1-2 Numbers 333761 and Higher
1-5 Safety Symbols ............. 1-2 6-2.2 Adjustment for Truck Serial ... 6-2
Numbers 333620 to 333760
2 OPERATION
6-3 Replacement of Disc Brake Parts. 6-3
2-1 General ................... 2-1
6-3.1 Parts Replacement for Truck .. 6-3
2-2 Operating Precautions ....... 2-1 Serial Numbers 333761
2-3 Before Operation ............ 2-2 and Higher
2-4 Instruments and Controls ..... 2-4 6-3.2 Parts Replacement for Truck .. 6-4
2-4.1 Steering Arm and ........... 2-4 Serial Numbers 333620 to
Control Head 333760
2-4.2 Lift/Lower .................. 2-5 6-3.2.1 Disc Brake Pad Replacement . 6-4
2-4.3 Battery Disconnect .......... 2-5 6-3.2.2 Brake Lever ............... 6-4
2-4.4 Optional Features ........... 2-5 6-3.3 Replacement of Brake Disc ... 6-5
2-5 Operation ................. 2-5 6-3.3.1 Disc Replacement For Truck 6-5
2-5.1 Forward and Reverse Travel. .. 2-5 Serial Numbers 333761
and Speed Control and Higher
2-5.2 Steering ................... 2-5 6-3.3.2 Disc Replacement For Truck 6-6
2-5.3 Stopping .................. 2-6 Serial Numbers 333620 to
2-5.4 Parking ................... 2-6 333760

• 3
2-5.5
2-5.6
2-5.7
Battery Charging ............
Load Handling ..............
Moving a Disabled Truck ......
PLANNED MAINTENANCE
3-1
3-2
General ...................
Monthly and Quarterly Checks .
2-7
2-7
2-7

3-1
3-1
7 TRANSMISSION, DRIVE WHEEL CASTER

7-1

7-2
7-3
WHEEL AND LOAD WHEEL SERVICING
Transmission Removal and ...
Disassembly
Drive Wheel Replacement ....
Caster Wheels .............
7-1

7-2
7-2
3-3 Battery Care ............... 3-1 7-3.1 Caster Wheel Assembly 90161 0 7-2
3-3.1 General ................... 3-1 7-3.2 Caster Wheel Assembly 901100 7-2
3-3.2 Battery Servicing ............ 3-1 7-4 Load Wheels .............. 7-4
3-4 Lubrication ................. 3-2
8 ELEVATION SYSTEM SERVICING
4 TROUBLESHOOTING 8-1 General .................. 8-1
4-1 General ................... 4-1 8-2 Ram Head Replacement ..... 8-1
5 STEERING ARM AND CONTROL 8-2.1 Non-telescopic Trucks ....... 8-1
HEADS SERVICING 8-2.2 Telescopic Trucks .......... 8-1
8-3 Yoke Sheave Replacement ... 8-1
5-1 General ................... 5-1
( Full Free-Lift)
5-2 Cold Conditioning ........... 5-1
8-4 Lift Chain Adjustment. ....... 8-1
5-3 Belly-Button Switch Adjustment . 5-2
8-4.1. Telescopic and ............. 8-1
5-4 Control Head Switch ......... 5-2
Non-Telescopic Trucks
Replacement
5-5 Speed Control Switch Return .. 5-4 8-4.2. Full Free Lift Trucks ......... 8-2
Spring Replacement 8-5 Lift Chain Replacement ...... 8-3
5-6 Steering Arm Return ......... 5-5 8-5.1 Non-telescopic and ......... 8-3
Spring Adjustment Telescopic Trucks
5-7 Steering Arm Return ......... 5-5 8-5.2 Full Free Lift and ........... 8-4
Spring Replacement 8-6 Lift Cylinder Removal ....... 8-5

• PDM0495
5-8
5-9
Pivot Tube Replacement ......
Electrical Control Cable .......
Replacement
5-7
5-9
8-6.1

8-6.2
Non-telescopic andTelescopic.
Telescopic
Full Free Lift ...............
8-5

8-5

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Section
8-7
8-8
TABLE OF CONTENTS (Cont.)

Mast Removal ..............

Lift Carriage and Mast ........
Replacement
Page
8-5
8-6
Section
9-7
9-7.1
Lift Cylinder Repair .........
Non-telescopic and .........
Telescopic
Page
9-11
9-11
•
8-9 Mast Lubrication Procedure .... 8-6 9-7.2 Full Free Lift ............... 9-11
8-10 Adjustable Straddles ......... 8-6
10 ELECTRICAL COMPONENTS
8-11 Base and Frame ............ 8-9
10-1 Electrical Control Panels ..... 10-1
8-11.1 Cabinet Door Latch .......... 8-6
10-2 Contactor Servicing ......... 10-1
8-11.2 Battery Compartment Cover ... 8-6
10-2.1 2nd Speed, 3rd Speed, ...... 10-1
Removal
Dynamic Brake Single
8-11.3 Battery Connector ........... 8-7 Pole Contactor Disassembly
Replacement
10-2.2 2nd Speed, 3rd Speed, ...... 10-2
9 HYDRAULIC SYSTEM SERVICING Dynamic Brake Single
9-1 Relieving System Pressure .... 9-1 Pole Contactor Reassembly
9-2 Line, Fitting, and Hose ........ 9-1 10-2.3 Forward-Reverse Double ..... 10-2
Replacement Pole Contactor Disassembly
9-3 Filter Replacement .......... 9-1 10-2.4 Forward-Reverse Double ..... 10-2
Pole Contactor Reassembly
9-4 Flow Control Valve ........... 9-1
9-5 Hydraulic Pump and ......... 9-6 10-3 Pump Motors .............. 10-4
Motor Assembly 10-4 Drive Motors ............... 10-4
9-5.1 Pump and Motor Assembly .... 9-6 10-5 Batteries .................. 10-4
016912 and 016922 10-6 High Speed Limit Switch ..... 10-4
9-5.2 Pump and Motor Assembly .... 9-6 10-7 Battery Chargers ........... 10-5

•
016936 11 OPTIONAL EQUIPMENT
9-6 Control Valve Service ........ 9-9
11-1 Keyswitch ................. 11-1
9-6.1 Control Valve Replacement .... 9-9
11-2 Hour Meter ................ 11-1
9-6.2 Disassembly of Lift Control .... 9-9
11-3 Battery Capacity Indicator .... 11-1
Valve
11-4 Remote Control ............ 11-1
9-6.3 Control Valve Adjustment ..... 9-9
9-6.4 Hydraulic Pump Motor Switch .. 9-11 12 ILLUSTRATED PARTS . . . . . . . . . . . . . . 12-1
Adjustment BREAKDOWN

LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 Name Plate ..................... 1-1 5-5 Control Head Push-button Switches . 5-4
1-2 Serial Number and Decal Location ... 1-3 5-6 Steering Arm and Pivot Cap ....... 5-6
1-3 PDM Lift Truck .................. 1-4 5-7 Pivot Tube Replacement. ......... 5-8
2-1 Load Center .................... 2-1 5-8 Electrical Control Cable .......... 5-10
2-2 Sample of Operator Check List ..... 2-3 Replacement
2-3 Control Handle .................. 2-4 6-1 Brake Engage/Disengage ......... 6-1
2-4 Lift/Lower Levers ................ 2-5 6-2 Adjustment For Truck Serial ....... 6-2
2-5 Optional Remote Lift/Lower Control .. 2-5 Numbers 333761
2-6 Steering Arm Braking Position ...... 2-6 and Higher
3-1 Lubrication Diagram .............. 3-3 6-3 Adjustment For Truck Serial ....... 6-2
4-1 Electrical Wiring Diagram .......... 4-6 Numbers 333620 to 333760
5-1 Schematic of Cold Conditioning ..... 5-1 6-4 Parts Replacement for Truck Serial . 6-3
Circuit Numbers 333761 and Higher
5-2 Location of Resistors and .......... 5-1 6-5 Parts Replacement For Truck Serial. 6-5

•
Thermal Cutout Switch Numbers 333620 to 333760
5-3 Belly-Button Switch Adjustment ..... 5-2 7-1 Transmission Assembly .......... 7-1
5-4 Control Head Assembly ........... 5-3 7-2 Transmission Removal ........... 7-3

ii PDM0495

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• Figure
7-3
7-3
7-5
8-1
LIST OF ILLUSTRATIONS (Cont.)

Caster Wheel Assembly 90161 0 .... 7-4

Caster Wheel Assembly 901100 .... 7-4
Load Wheels ................... 7-5
Standard Masts (Nontelescopic) .... 8-2
Page Figure
12-10A
12-11
12-12
12-13
Cold Conditioning Electrical .......
Decal Location .................
Adjustable Straddles .............
Load Wheels ...................
Page
12-20
12-22
12-23
12-24
8-2 Standard Masts (Telescopic) ....... 8-3 12-14 Caster Wheels ................. 12-25
8-3 Inner and Outer Mast (Full Free Lift) . 8-4 12-15 Caster Wheels ................. 12-26
8-4 Lift Carriage (Shaft Type) Telescopic . 8-7 12-16 Standard Masts (Nontelescopic) .... 12-27
and Nontelescopic and FFL 12-17 Standard Masts (Telescopic) ...... 12-28
8-5 ITA Lift Carriage ................. 8-8 12-18 Inner and Outer Mast Full Free Lift .. 12-30
8-6 Adjustable Straddles ............. 8-9 12-19 Lift Carriage (Shaft Type) ......... 12-31
8-7 Base and Frame ................. 8-10 Telescopic and Nontelescopic
9-1 Hydraulic Installation (TEL AND ..... 9-2 and FFL
NON-TEL) 12-20 ITA Lift Carriage ................ 12-32
9-2 Hydraulic Installation (FFL) ........ 9-3 12-21 Lift Control Valve assembly ....... 12-34
9-3 Hydraulic Panel Assembly ......... 9-4 12-22A Hydraulic Installation (TEL AND .... 12-35
9-4 Hydraulic Panel Assembly ......... 9-5 NON-TEL)
9-5 Hydraulic Pump 016912 and 016922. 9-7 12-22B Hydraulic Installation (FFL) ........ 12-36
9-6 Hydraulic Pump 016936 ........... 9-8 12-23 PDM Hydraulic Panel Assembly .... 12-37
9-7 Hydraulic Control Valve Assembly ... 9-10 12-24 PDM Hydraulic Panel Assembly .... 12-38
9-8 Lift Cylinder (Non-Telescopic ....... 9-12 12-25 Remote Installation .............. 12-39
and Telescopic) 12-26 Remote Installation (Continued) . . . . 12-42
9-9 Lift Cylinder Full Free Lift .......... 9-13 12-27 Lift Cylinder (TEL AND NON-TEL) .. 12-44
10-1 Single Pole; Contactor, 2nd Speed, .. 10-1 12-28 Lift Cylinder (FFL). . . . . . . . . . . . . . . 12-46
3rd Speed, Dynamic Brake 12-29 Pump and Motor Assembly 016936 . 12-48

• 10-2

10-3
10-4

10-5
Double Pole Contactor Forward, .... 10-3
Reverse
High Speed Limit Switch .......... 10-5
"SMART" Battery Charger ......... 10-5
004975-01 Schematic Diagram
30-Amp Timer Battery Charger ..... 10-6
Schematic
12-30 Hydraulic Pump . . . . . . . . . . . . . . . .
12-31 Pump Motor 905035 . . . . . . . . . . . . .
12-32 Pump Motor 904140 .............
12-33 Drive Motor 016042 . . . . . . . . . . . . .
12-34 Contactor Panel Assembly . . . . . . . .
12-35 Single Pole Contactor, 2nd Speed,. .
3rd Speed, Dynamic Brake
12-49
12-50
12-51
12-52
12-54
12-56

12-1 Control Head Assembly Part ....... 12-2 12-36 Double Pole Contactor, Forward, ... 12-57
Number 505050 Reverse
12-2 Control Head Push Button Switches . 12-4 12-37 "Smart" Charger 004975-01 ....... 12-58
12-3 Cold Conditioning, Control Head .... 12-5 12-38 30-Amp Battery Charger .......... 12-59
Assembly Part Number 505050 12-39 Optional Hour Meter Installation .... 12-60
12-4 Steering Arm, Pivot Cap and ....... 12-6 12-40 Battery Capacity Indicator Wiring ... 12-61
Electrical Control Cable Diagram Systems Without
12-5 Pivot Tube Assembly ............. 12-8 Lockout
12-6 Brake and Linkage ............... 12-1 0 12-41 Battery Capacity Indicator Wiring ... 12-62
12-7 Brake and Linkage ............... 12-12 Diagram Systems With
12-8 Transmission Assembly ........... 12-14 Lockout
12-9 Base and Frame ................. 12-16 12-42 Optional Key Switch ............. 12-63
12-10 Base and Frame-Electrical ......... 12-18

LIST OF TABLES
Table Page Table Page
2-1 Operator Checks ................ 2-2 3-3 Hydraulic Oil Capacity Chart ....... 3-2
2-2 Control Handles ................. 2-4

•
3-4 Lubrication Chart ............... 3-3
3-1 Inspection and Service Chart ....... 3-1
3-2 Recommended Lubricants and Oils .. 3-2 4-1 Troubleshooting Chart ........... 4-1

PDM0495 iii

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 OPERATOR INSTRUCTIONS

Do not operate this truck unless you have been trained

and authorized to do so and have read all warnings and
WARNING
Do not overload truck. Check capacity plate for load
weight and load center information.
•
instructions in operator's manual and on this truck.
When using forks, space forks as far apart as load will
Do not operate this truck until you have checked its permit. Before lifting, be sure load is centered, forks are
condition. Give special attention to Tires, Horn, Lights, completely under load, and load is as far back as
Battery, Controller, Lift System, (including forks or at- possible against load backrest.
tachments, chains, cables and limit switches), Brakes, Do not handle unstable or loosely stacked loads. Use
Steering Mechanism, Guards and Safety Devices. special care when handling long, high or wide loads to avoid
losing the load, striking bystanders, or tipping the truck.
Operate truck only from designated operating position.
Never place any part of your body into the mast structure or Do not handle loads which are higher than the load
between the mast and the truck. Do not carry passengers. backrest or load backrest extension unless load is se-
cured so that no part of it could fall backward.
Observe applicable traffic regulations. Yield right of way
to pedestrians. Slow down and sound hom at cross Elevate forks or other lifting mechanism only to pick up
aisles and wherever vision is obstructed. or stack a load. Watch out for obstructions, especially
overhead.
Start, stop, travel, steer and brake smoothly. Slow down
Do not lift personnel except on a securely attached
for turns and on uneven or slippery surfaces that could
specially designed Work Platform. Use extreme care
cause truck to slide or overturn. Use special care when
when lifting personnel. Make sure mast is vertical, place
traveling without load as the risk of overturn may be

•
truck controls in neutral and apply brakes. Lift and lower
greater.
smoothly. Remain in operating position or immediate
Travel with lifting mechanism as low as possible. Always vicinity as long as personnel are on the Work Platform.
look in direction of travel. Keep a clear view, and when Never transport personnel on forks or Work Platform.
load interferes with visibility, travel with load or lifting Do not allow anyone to stand or pass under load or lifting
mechanism trailing, except when traveling downhill. mechanism.
Use special care when operating on ramps-travel When leaving truck, neutralize travel control. Fully lower
slowly, and do not angle or turn. Travel with lifting lifting mechanism and set brake. When leaving truck
mechanism or load downhill. unattended, also shut off power.

PREPARATION FOR USE

Upon receipt, visually inspect the truck. If any damage Before the lift truck is moved, the battery must be
is found, report it to the carrier and to your Big Joe dealer checked, recharged if necessary, and connected. Refer
immediately. to "Battery Care" in Section 3 for battery checking
instructions.
Remove cardboard banded to truck. Check lift truck for Refer to Section 2 for operating instructions of
scratches and dents. Check to make sure that the lift the brakes and lift control.
chains are free of slack. Inspect for oil leaks and loose
wiring connections. Make certain that all accessories If you do not obtain the proper results, or if improper
and attachments that were ordered are supplied. operation occurs, refer to troubleshooting in Section 4 .

iv PDM0495
•
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•
SECTION 1
DESCRIPTION

1-1. INTRODUCTION.
This publication describes the Power Driven Medium
Duty (PDM) lift truck manufactured by Big Joe Manufac-
turing Company, Lincolnwood, Illinois, 60646. Included
are operating instructions, planned maintenance in-
structions, lubrication procedures, corrective mainte-
nance procedures and a complete parts list with parts
location illustrations.
By following the recommendations contained in this
manual, you will receive many years of dependable
service from your Big Joe lift truck.
The lift truck is identified by a model number. The model
number shows truck capacity, fork and mast type, and
lift height. A typical model number is explained below.

PDM 20-106
Lifting capacity
in hundreds of - - - - - ' -
J
pounds

• Lift Height
R3231

Figure 1-1. Name Plate

The model number will be found on the name plate
(Rgure 1-1) along with the serial number, lifting capacity, The battery-powered lift truck is quiet and without ex-
and load center. Figure 1-2 shows the location and haust fumes.
identification of the decals. Also listed is the location of
the trucks serial number and name plate. Figure 1-3 The reversible DC motor propels the lift truck in forward
shows the locations of the trucks main components and and reverse direction throughout the available speed
controls. range. The PDM lift truck can be driven with forks raised
or lowered; however, the speed is restricted when the
forks are raised above a preset limit.
1-2. GENERAL DESCRIPTION.
1-3. SAFETY FEATURES.
The self-propelled PDM truck, Figure 1-3, lifts and trans-
ports payloads on adjustable forks. The PDM 20 can lift The PDM is designed and engineered to provide safety
up to 2000 pounds, the PDM 25 can lift up to 2500 for operator and payload. Some of the safety features
pounds, and the PDM 30 can lift up to 3000 pounds at incorporated into the design are:
24 inch load centers.
Dead-man brake to apply mechanical brake and cut off
The forward and reverse motion is controlled by a speed drive power when the steering arm is released.
controller switch in the control head. Stopping and turn-
Belly-button switch to reverse truck should the operator
ing is controlled by the steering arm. Lift and Lower is

•
accidentally pin himself against a wall or obstruction.
controlled by either a lever mounted on the chassis,
optional pushbutton controls located on the steering High speed limit switch to restrict speed when lift car-
arm, or a control box attached by a coiled cord. riage is raised above the preset limit.

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 •
All control functions automatically return to "OFF' when 1-5. SAFETY SYMBOLS.
released.
WARNING: This WARNING sign denotes a hazard. It
Externally accessible quick-disconnect battery plug.
calls attention to a procedure, practice or
Separately fused control circuits and power circuits. the like, which if not correctly performed
Readily accessible HORN button. or adhered to could result in personal
injury.
Lift carriage backrest to help stabilize the load.
Pressure compensated flow control valve regulates CAUTION: This CAUTION sign denotes a hazard. It
maximum lowering speed. calls attention to a procedure, practice or
the like, which if not correctly performed
High visibility color scheme of truck provides visual alert
of trucks presence. or adhered to could result in personal
injury or damage to the equipment.
1-4. OPTIONS AND ACCESSORIES. IMPORTANT:This heading calls attention to a proce-
Big Joe offers many options and accessories for the dure, which if not followed, may impede
PDM lift truck such as: the operation or normal flow of a servicing
Key switch or repair procedure.
Remote Lift Control
Cold Conditioning
Battery Capacity Meter
Hour Meter
Lift Limit Switch
Lift Limit Override Switch
Larger capacity batteries with corresponding
battery chargers
Transistor Control (Refer to Supplement 228 for trucks

•
serial number 338388 and higher) (Refer to Supplement
187 for trucks serial number 333620 to 338387).

1-2 PDM0495
•
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•
CAUTION

• CAUTION

SERIAL NUMBER
LOCATION UNDER
DOOR ON FRAME

R5413

Figure 1-2. Serial Number and Decal Location

• PDM0495 1-3

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 •
RAM
HEAD

LIFT
CONTROL
OUTER
MAST CONTROL
HEAD

//

BATTERY STEERING
COMPARTMENT HEAD

CABINET

•
DOOR

LIFT // BATTERY
CARRIAGE COMPARTMENT
//

RS414

1-4
Figure 1-3. PDM Lift Truck

PDM0495
•
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•
SECTION 2
OPERATION

1. SEE SUPPLEMENT 220 FOR TRANSISTOR 3. Do not exceed the rated capacity (see name plate).
TRUCKS SERIAL NUMBER Overloading may result in damage to the hydraulic
334631 AND HIGHER. system and structural components.
2. SEE SUPPLEMENT 207 FOR TRANSISTOR 4. Do not handle unstable or loosely stacked loads.
TRUCKS SERIAL NUMBER Use special care when handling long, high, or wide
333620 TO 334630. loads to avoid tipping, loss of load, or striking
bystanders.
2-1. GENERAL 5. Center and carry the load as far back as possible
This section gives detailed operating instructions for the toward the lift carriage back rest. Do not pick up
PDM lift truck. The instructions are divided into the loads on the tips of forks. The center-of-gravity of
various phases of operations, such as operating the lift, the load must not exceed the load center listed on
the name plate. See Figure 2-1 for load center
driving, and stopping. Routine precautions are included
for safe operation. limitations.
6. Pick up loads on both forks. Do not pick up loads
2-2. OPERATING PRECAUTIONS. on only one fork.

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

WARNING: Improper operation of the lift truck may possible.
result in operator injury, or load and/or lift
truck damage. Observe the following pre- 8. When stacking pallets in racks and it is necessary
cautions when operating the PDM lift to move the load in the raised position, use caution.
truck. Operate truck smoothly.

• 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-

9. Check for obstructions when raising or lowering the
lift carriage.

10. Apply the brake gently except in cases of emergency.

11. Observe applicable traffic regulations. Yield right of
way to pedestrians. Slow down and sound horn at
tion or service has been completed. See table 3-1. cross aisles and wherever vision is obstructed.

SAFE UNSAFE CENTER OF GRAVITY

OF LOAD
CENTER OF GRAVITY
OF LOAD '' , ..1

'' " "

' .I " '' ""
r-----r--.,"
', I

'I " '' " "

' "' I

LOAD CENTER
IN INCH~S
'""
,..":
,
',
l-- -----; r /
- -
'
J':- -
I

/ I ' LOAD CENTER "" I ',

/ I ' IN INCHES / : ',
I !t __ " " ', '
I
I I
....... ~
I
I
LOAD CENTER '- --411
IN INCHES LOAD CENTER
IN INCHES

•
R3814

Figure 2-1. Load Center

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 •
12. Operate truck only from a walking position. Never CAUTION: A QUALIFIED SERVICE TECHNICIAN
place any part of your body between the mast should check the truck monthly for proper
uprights. Do not carry passengers. lubrication, proper fluid levels, brake
13. Do not allow anyone to stand or pass under load or maintenance, motor maintenance and
lifting mechanism. other areas specified in the Section 3.

WARNING: If the truck is found to be unsafe and in

2-3. BEFORE OPERATION need of repair, or contributes to an unsafe
Table 2-1 covers important inspection points on PDM lift condition, report it immediately to the des-
truck which should be checked prior to operation. De- ignated authority. Do not operate it until it
pending on use, some trucks may require additional has been restored to a safe operating
checks. condition. Do not make any unauthorized
repairs or adjustments. All service must
Rgure 2-2 shows a sample format for a Operator Check-
be performed by a qualified maintenance
list, which can be modified as necessary to fit your
technician.
operation.

WARNING: Periodic maintenance of this truck by a

QUALIFIED TECHNICIAN is required.

Table 2-1. Operator Checks

ITEM PROCEDURE ITEM PROCEDURE

Transmission Check for signs of fluid leakage. Hydraulic controls Check operation of lift and lower
and hydraulic to their maximum positions.
systems. Check that brakes actuate when
Brakes

•
Forks Check for cracks and damage; steering arm is raised to upright
and, that they are properly position, and when lowered to
secured. horizontal position. Check that
dynamic brake (if so equipped)
Chains, cables Check that they are in place,
actuates when dynamic brake
and hoses properly secured and not
pushbutton on control handle is
damaged.
pressed.
Guards and Check that safety guards are in
load backrest Deadman/Parking Check that steering arm raises
place, properly secured and not
damaged. brake to upright position when
released and brake applies.
Safety signs Check that warning labels,
Battery disconnect Check that battery can be
nameplate, etc., are in good
condition and legible. disconnected and reconnected.
Check for connector damage.
Hom Check that horn sounds when
operated. Battery charge Check that battery capacity
meter (if equipped) is on "P'.
Steering Check for binding or looseness
in steering arm when steering. High speed Allow for enough space to oper-
limit switch ate truck in high speed. Elevate
Travel controls Check that speed controls on forks approximately two feet,
control handle operate in all then test drive truck to check if
speed ranges in forward and re- high speed is cut out.
verse and that belly button
switch functions.
Wheels Check drive wheel for cracks or
damage. Move truck to check

2-2
load and caster wheels for free-
dom of rotation.

PDM0495
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• JL
•iiilL&
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Electric Truck
Daily Operator Check-Off List

Date Operator

Truck No. Model No.

Dept. Shift
Hour Meter
Reading-Drive Hoist

Check O.K.(,.,.) Need Maintenance

lires
Load Wheels
Hom

•
Lift-Lower Control
Attachment Operation
Forward & Reverse Controls

Steering
Electrical Brakes
Mechanical Brake
Hydraulic Leaks, Cylinders,
Valves, Hoses, Etc.

R5699
.
F1gure 2-2. Sample of Operator Check List

• PDM0495 2-3

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 •
2-4. INSTRUMENTS AND CONTROLS Table 2-2. Control Handles

2-4.1. Steering Arm and Control Head.

The steering arm and control handle (See Figure 2-3) 1. SEE SUPPLEMENT 220 FOR TRANSISTOR
provide controls for steering, forward and reverse speed TRUCKS SERIAL NUMBER 334631
control, braking, and horn. Control handles on some AND HIGHER.
models have pushbuttons for raising and lowering the 2. SEE SUPPLEMENT 207 FOR TRANSISTOR
forks. Table 2-2 lists optional control handles. Control TRUCKS SERIAL NUMBER 333620 TO
handles on all models have a "belly-button" reversing 334630.
switch which reverses the direction of the truck upon Type Part Numbers
contact with the operator. Standard 505050-01
Remote Lift
in Handle 505050-02
Remote Lift
and Lower
in Handle 505050-03

REVERSE
1.SEE SUPPLEMENT 220 FOR SPEED SPEED
CONTROL

•
CONTROL TRUCKS SERIAL
NUMBER 334631 AND HIGHER.
2.SEE SUPPLEMENT 207 FOR
TRANSISTOR SPEED CONTROL
TRUCKS SERIAL NUMBER
333620 TO 334630.
IF ROTATING GRIPS
ARE PREFERRED.
PINS

FORWARD
SPEED
CONTROL
R3974

Figure 2-3. Control Handle

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•
2-4.2. Lift/Lower.
All models come standard with a lifVIower control lever
mounted near the steering arm. See Figure 2-4

2-4.3. Battery Disconnect.

A battery disconnect is mounted near the rear of the
LIFT/LOWER
battery compartment. Pulling the disconnect removes CONTROL
all power from truck circuits in the event of an emer- LEVER
gency.

2-4.4. Optional Features.

The optional remote lift/lower control (if equipped)
allows the operator to raise and lower the forks while
standing away from the control handle. See Figure 2-5.
Other options are the battery capacity indicator, hour
meter and key switch, which mount on the panel near
the control handle. The battery capacity indicator moni-
tors the battery discharge rate to indicate the remaining
battery capacity. The hour meter records the accumu-
lated hours that electrical energy is being drawn from
the battery to run the pump and drive motors. The key
switch provides added security to the truck, preventing
unauthorized personnel from operating the machine.
R5415

•
2-5. OPERATION
Figure 2-4. Lift/Lower Lever
2-5.1. Forward and Reverse Travel and Speed
Control.
All directional and speed controls are located on the
control handle. See Rgure 2-3.
Forward and reverse are controlled by rotating the
speed control lever as shown. The lever is spring loaded
to return to neutral when released. Further rotation in
either direction will progress the truck from slow to
maximum travel speed.
To change directions or to stop the truck, rotate the
speed control lever in the opposite direction. The truck
will come to a stop and then, unless the controls are
returned to the center neutral position, accelerate in the
opposite direction.
2-5.2. Steering.
Moving the control handle (which connects to the steer-
ing arm) ~ight or left will turn the truck right or left. When
maneuvering around comers, make square turns and
be sure there is adequate clearance.

R3962

Figure 2-5. Optional Remote Lift/Lower Control

• PDM0495 2-5

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 •
2-5.3. Stopping. return to the vertical position in the event the driver
releases the control handle during operation. This
Stop the truck as gradually as possible. Unnecessary
is known as deadman braking.
rapid stopping could be hazardous. Load could become
unstable. 4. Dynamic brake: The dynamic brake serves as a
secondary braking system completely independent
There are four possible ways to stop the truck:
from the mechanical brake. Pressing the dynamic
1. Plugging: This electrical braking function consists brake pushbutton applies a constant DC voltage
of rotating the speed control lever in the opposite across the drive motor field coils to stop the motor.
direction of travel and then releasing it when the
CAUTION: The dynamic brake pushbutton should not
truck stops. Plugging is a convenient way to stop
be held in place longer than one or two
the truck during normal operation. If the control is
seconds. Excessive use may blow the 40
not released, the truck will accelerate in the oppo-
Amp fuse, which will render dynamic
site direction.
brake inoperative.
2. Steering arm in horizontal position (See Fig-
ure 2-6): Lowering the steering arm to the horizon- 2-5.4. Parking.
tal position applies brake pad pressure to the brake When parking the truck, do not obstruct traffic lanes or
disc. Lowering the steering arm below the horizon- aisles.
tal position increases the braking force and de-en-
ergizes the controls. 1. Park the truck in its designated parking area.
3. Steering arm in vertical position (See Fig- 2. Raise the steering arm until vertical to apply the
ure 2-6): Raising the steering arm to near vertical parking brake.
position applies brake pad pressure to the brake 3. Fully lower forks.
disc. Further vertical positioning increases the
braking force and de-energizes the controls. This 4. Turn key switch (if so equipped) to off position.
position serves as a parking brake. As a safety Remove key for added security.
precaution, the steering arm is spring loaded to 5. Pull out battery disconnect.

CONTROLS ARE ENERGIZED.

MECHANICAL BRAKE
STARTS TO ENGAGE.
•
CONTROLS ARE
DE-ENERGIZED.
MECHANICAL BRAKE
IS ENGAGED.

SIDE VIEW

R3629

2-6
Figure 2-6. Steering Arm Braking Position

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•
2-5.5. Battery Charging 6. Make sure the load is against the backrest and then
raise the forks until the pallet clears the rack.
Refer to Document 245 for battery safety and
maintenance. 7. Move the truck away from the rack until the load
clears the rack and then lower the forks.
8. Lead the truck by the control handle with the load
trailing except when in confined areas. Ramps

~
should be traveled with operator uphill of truck
MELD ® EYES NO
• SPARD
SULFURIC
ACID
when empty, or operator downhill of truck when
load on forks.
EXPLOSIVE CAll WISE
9. Always look in the direction of travel. Move slowly
GASESw CAUSE • IUIIfS IUIDNOSOII
IIJIDif.SS DR IIUURT • SMDllliG SMilE IIURIII and check clearances when approaching obstruc-
tions.
10. Do not make sudden starts and stops. Operate
truck smoothly and gradually.
11. Travel slowly and squarely around comers. Re-
member that the trailing load wheels do not follow
the turn path of the drive wheel. Instead they tend
NOTE Battery charging instructions are contained in to cut the comer.
Section 3.
12. Line up the truck with the unloading area.
2-5.6. Load Handling. 13. Stop the truck and raise or lower the forks until the
pallet is in position with the unloading area.
WARNING: Handle only loads arranged for stability,
and always use caution. Raise and lower 14. Check the load alignment with surrounding objects.

•
the load smoothly to prevent the load from 15. Be careful not to damage or move adjacent loads
falling. and objects.
WARNING: Always be sure the load and load center 16. Slowly move into position.
are within the capacity of the truck. If in
17. Lower the forks until the load is resting on its own.
doubt, check the nameplate.
Be sure there is no downward force of the forks on
1. Approach the load slowly. the rack or floor.

2. Stop the truck when the forks are just in front of the 18. Move the truck back until the forks are clear of the
load. pallet.
3. Adjust the forks to the maximum practical width to 19. If forks are elevated, lower to travel position.
support the load to be lifted.
2-5.7. Moving a Disabled Truck
4. Raise or lower the forks until they are properly
aligned with the pallet openings. Do not attempt to move a disabled truck. Notify your
supervisor or proper authority.
5. Move the truck slowly into position so that the forks
are centered about the load .

• PDM0495 2-7

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NOTES

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•
SECTION 3
PLANNED MAINTENANCE

3-1. GENERAL. 3-3.2. Battery Servicing.

Planned maintenance consists of periodic visual and Refer to Document 245 for battery safety and
operational checks, parts inspection, lubrication, and maintenance.
scheduled maintenance designed to prevent or dis-
cover malfunctions and defective parts. The operator
performs the checks in Section 2, and refers any re-
quired servicing to a qualified maintenance technician
who performs the scheduled maintenance and any re-
quired servicing. ~ao EYES
&
SULFURIC
ACID
3-2. MONTHLY AND QUARTERLY CHECKS. EXPLOSIVE CAl WISE
GASESc:AN CAUSE IUIDmSIII
Table 3-1 is an inspection and service chart based on SEVERE IIURIIS
normal usage of equipment eight hours per day, five
days per week. If the lift truck is used in excess of forty
hours per week, the frequency of inspection and service
should be increased accordingly. These procedures
must be performed by a qualified service technician or
your Big Joe service representative.
3-3. BAITERY CARE.
The battery cells are accessed by opening the top cover
3-3.1. General. of the battery. Use the following procedure:
The life of the battery can be extended by giving it proper 1. Obtain a battery hydrometer.

•
care. Perform a daily check of the battery whether or not
the equipment is in daily use. DO NOT overcharge the NOTE: These can be obtained from a local hardware
battery or battery life will be shortened. DO NOT allow store or automotive shop.
battery to become completely discharged (specific grav-
ity 1.150 or less). This will also greatly shorten battery 2. Use the hydrometer to check specific gravity of
life. each cell.
Table 3-1. Inspection and Service Chart

VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check condition of drive motor commutator, brushes and springs
Monthly Check condition of pump motor commutator, brushes and springs
Monthly Check mechanical brake for proper operation
Monthly Check load wheels for wear
Monthly Check caster wheels for wear
Monthly Check drive wheel for wear
Monthly Inspect wiring for loose connections and damaged insulation
Monthly Inspect contactor tips for excessive pitting and wear
Monthly Check deadman brake switch for proper operation
Monthly Check lift chain tension
Monthly Lubricate Unit (See Table 3-4)
Quarterly Check lift cylinder for leakage

• Quarterly
Semi-annually

PDM0495
Check for excessive jerking of steering arm when stopping or starting
Replace hydraulic filter assembly

3-1

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 •
NOTE: Battery specific gravity readings should agree
Table 3-2. Recommended Lubricants and Oils
within± 0.025 from cell to cell. If variation is
greater, the battery may have to be repaired or No.1 Transmission oii-EP SAE 80W-90
replaced. Transmission oii-EP SAE 10W30 (Note)
CAUTION: Be sure that no cell plates are exposed Transmission oil capacity is 3 pints.
(not covered by fluid) before charging.
Add distilled water sufficient to just cover No.2 Grease-Lithium base, general purpose.
top of cell plates.
No.3 Hydraulic oil-Heavy duty with a viscosity
CAUTION: Use distilled water. Impurities in tap water of 150 SUS (in temperatures below 32°F
will damage battery plates. use 100 SUS) foam suppressing agent
and rust and oxidation inhibitors. See
3. Charge battery as necessary. Table 3-3 for oil capacity.
NOTE: A fully charged battery has a specific gravity of Big Joe Part No. 900855 (1 gallon)
1.260 to 1.275. 900893 (1 quart)
055784 (Note)
4. After charging, check water level in each cell again.
Water level must cover plates but not be higher than NOTE: USED ON COLD CONDITIONED TRUCKS
the base of the battery cell filler neck.

3-4. LUBRICATION.
Refer to table 3-2 for the recommended types of grease
and oil, and table 3-3 for hydraulic oil capacities. Table
3-4 in conjunction with Figure 3-1 identifies the items Table 3-3. Hydraulic Oil Capacity Chart
requiring lubrication. LIFT OIL
HEIGHT
60in
106 in
106 in*
130 in
CAPACITY
10 qts
10 qts
14 qts
10 qts
•
130 in* 14 qts
154 in 10 qts

* FFL trucks

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• 2

3
4

//
//
1

// -- - - 5
//

• R5416

Figure 3-1. Lubrication Diagram

Table 3-4. Lubrication Chart

FIG. 3-1 METHOD OF TYPE

REF ITEM APPLICATION J!ABLE3·~- NOTES
1 Lift carriage rollers Gun No.2 Pressure lubricate.

2 Chain sheaves Gun No.2 Pressure lubricate.

3 Outer and inner masts Brush No.2 Clean off old grease and apply a thin coat
the full length of mast where rollers touch.
4 Free Lift Slide bar
(Telescopic Trucks) Brush No.2 Clean off old grease and apply a thin coat
the full length of slide bar where ram head
touches.
5 Transmission Can No.1 Fill to hex plug (fill level plug) level.
Remove vent and fill through vent hole .

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NOTES

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•
SECTION 4
TROUBLESHOOTING

1. SEE SUPPLEMENT 220 FOR CONTROL 4-1. GENERAL

HEAD ON TRANSISTOR TRUCKS SERIAL Table 4-1 serves as a guide to determine possible
NUMBER 334631 AND HIGHER. causes of trouble. The table is divided into five main
2. SEE SUPPLEMENT 207 FOR CONTROL categories: Truck dead: trouble with travel: trouble with
HEAD ON TRANSISTOR TRUCKS SERIAL braking: trouble with lifting or lowering, and Miscellane-
NUMBER 333620 TO 334630. ous malfunctions. Refer to electrical wiring diagram
3. SEE SUPPLEMENT 187 FOR CONTROLLER (Figure 4-1) as a supplement to the troubleshooting
ON TRANSISTOR TRUCKS SERIAL chart or when tracing an electrical circuit.
NUMBER 333620 TO 338387.
4. SEE SUPPLEMENT 230 FOR CONTROLLER
ON TRANSISTOR TRUCKS SERIAL
NUMBER 338388 AND HIGHER ..

Table 4-1. Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

TRUCK DEAD
Truck will not run forward or in a. 300-Amp fuse blown. Check fuse and replace if defective.
reverse, nor will lift system op-
erate.

•
b. Battery dead or discon- Check battery quick-disconnect plug.
nected. Check battery (See Section 3).
c. Defective key switch. Check and replace if required.
d. Defective wiring. Check for open circuit Repair as required.
TROUBLE WITH TRAVEL Check all wiring. A loose con- Tighten all loose connections before
nection may be the cause of further troubleshooting.
malfunction.

Truck does not run forward a. 15-Amp control circuit fuse Check fuse and replace if defective.
or reverse. Everything else is blown.
normal.
b. Shorted dynamic brake Check brake switch and relay and
switch or dynamic brake re- replace if defective.
lay.
c. Defective dead-man brake Check and replace if required.
switch.
d. Main wire harness cut. Replace.
e. Belly button switch Replace.
defective.
f. Shorted optional travel cut- Check and replace if required.
out.
Truck runs forward, but not a. Defective speed control Check for positive DC voltage at
in reverse.

••
switch or defective contactor. number 1-wire on reverse contactor. If
not present when steering arm is in
operating position and speed control is
in reverse, speed control switch is

PDM0495 4-1

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 •
Table 4-1. Troubleshooting Chart (Continued)
defective. If voltage is present,
contactor is defective.
Truck runs forward, but not b. Belly button switch out of Adjust or repla<?e.
in reverse. (continued) adjustment or defective.
Truck runs in reverse, but Defective speed control switch Check for positive DC voltage at
not in forward. or defective contactor. number 2 wire on forward contactor. If
not present when steering arm is in
operating position and speed control is
pressed for forward travel, speed
control switch is defective. If voltage is
present, contactor is defective.
Truck runs forward and in re- a. Third speed cutout switch Adjust or replace.
verse at slow speed; will not out of adjustment or defec-
run at higher speeds. tive.
b. Defective second and/or Check coils for continuity. Check
third speed contactors. contacts for excessive wear. (A black
appearance where tips make contact is
normal). Repair or replace as required.
c. Defective optional time de- Check for continuity and replace as
lay relay(s). required.
Truck runs forward and in re- Defective or open speed Check for clean, tight connections.
verse at second or third speed control resistor. Check resistor for continuity and
only. Truck does not move replace or repair as required.

•
when control is in first speed
position. Everything else is
normal.
Truck runs at second or a. Defective 2nd or 3rd speed Check for shorted contacts on 2nd or
third speed when control is contactor. 3rd speed contactor.
in the first speed position.
Everything else is normal.
b. Defective speed control Check switches.
switch.
c. Shorted speed control resis- Check wiring of resistor..
tor.
TROUBLE WITH BRAKING
Mechanical brake does not a. Brake linkage in need of Adjust mechanical brake (see
stop truck properly. adjustment. paragraph 6-2).
b. Disc brake pads worn. Replace pads and readjust mechanical
brake.
Mechanical brake grabs when Brake linkage over adjusted. Adjust mechanical brake (see
steering arm is in operating po- paragraph 6-2).
sition.
Dynamic brake does not a. 40-Amp fuse blown. Check and replace fuse.
stop truck.
b. Defective brake switch, If click is heard when dynamic brake
brake relay, or brake resis- pushbutton is pressed, check brake
tor. resistor and relay contacts. If no click,

4-2 PDM0495
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•
Table 4-1. Troubleshooting Chart (Continued)

check brake switch and coil of relay.

Repair or replace defective part.
TROUBLE WITH LIFTING Oil level too low. Check hydraulic oil level. Rll hydraulic
OR LOWERING reservoir so that oil is shown full on
dipstick (approximately 2 inches from
top of reservoir) with the lift carriage fully
lowered, before further troubleshooting.
Tighten all electrical connections.
Lift carriage does not rise; a. Defect in electrical system. a. If pump motor does not run when
everything else is normal. LIFT control is in UP position, de-
feet is in pump solenoids, or pump
motor. Check for positive DC volt-
age at pump motor to locate defect.
Repair or replace defective part.

b. Check switch on control valve. Ad-

just or replace as necessary.

b. Defect in hydraulic system. a. Check for pinched hoses. Check

pump for proper operation. Replace
if necessary.
b. Check flow control valve near base
of lift cylinder. Check for defect in lift

•
cylinder.

Lift carriage does not lower; Control valve defective or de- Check control valve for proper action.
everything else is normal. feet in hydraulic system. Check for obstruction in the hydraulic
line. Repair as required.
Forks creep downward un- Leak in hydraulic system, Look for loose fittings in the hydraulic
der load; everything else is packing, control valve, or line, pump for leakage back into the
normal. pump. reservoir and oil on top of packing.
Repair fittings or replace pump as
required. Replace pressure relief valve.
Oil sprays or flows from the Defective packing in lift cylin- Overhaul the lift cylinder and install
top of the lift cylinder. der. new packing, seal, and wiper ring.

Oil foaming in vent for hy- Leak in the suction line between Check oil filter. Replace if necessary.
draulic reservoir. the pump and the reservoir. Tighten fitting. Inspect line and replace
if necessary.
Oil splashes out of vent Oil level too high. Drain, then refill reservoir when lift
when lowering forks. carriage is in the lowest position.
Squealing sounds when a. Oil level too low. Add oil to reservoir.
forks are raised.
b. Dry channels in mast. Apply grease.
c. Defective bearing. Replace bearing.
Forks do not lift to top. a. Oil level too low. Add oil to reservoir.
Pump motor runs.
b. Load heavier than capacity. Refer to nameplate for maximum load

• capacity.
c. Defective pump or motor. Replace.

PDM0495 4-3

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Oil leaks at throttle valve
release cam.
Table 4-1. Troubleshooting Chart (Continued)

Defective 0-rings in throttle

valve body.
Replace 0-rings around release cam.
•
Control valve spring- a. Broken springs. Replace springs.
centered handle does not
return to neutral.

b. Foreign particles. Clean system and valve.

c. Misalignment of operating Check linkage for binding condition.

linkage.

Load drops when LIFT a. Dirt or foreign particles Disassemble, clean and reassemble.
control is moved from lodged between check
neutral to UP position. valve poppet and seat.

b. Scored check ball. Replace check ball.

c. Defective check ball seat in Lap new check ball body seat.
valve body.

No motion, slow or jerky ac- a. Load heavier than capacity. Refer to nameplate for maximum lift
capacity.

•
tion of hydraulic system.
b. Defective lift cylinder. Rebuild or replace.

MISCELLANEOUS

Steering arm does not a. Return spring improperly Readjust spring tension {see
return to the upright adjusted. paragraph 5-6).
position.

b. Binding brake linkage or Check and free the binding item.

electrical cable.

c. Broken spring Replace.

Truck moves forward in low a. Belly-button reversing Check for short, and repair or replace
speed when arm is pulled switch defective. as necessary.
down.
b. First speed forward switch Replace.
defective.

c. Forward contactor stuck Repair or replace.

closed.

Steering arm jerks exces- a. Worn pivot tube bushings. Replace upper and lower pivot tube
sively when starting or stop- bushings.
ping the truck.

b. Drive tire worn or mounted

incorrectly.
Repair or replace.

PDM0495
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•
NOTES

• PDM0495 4-5

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 300A
A.C.INPUT

Ill
1T
40A 15A
KEYSWITCH
r~~,
I I

•
B

DYNAMIC
BRAKE
RESISTOR

S2

CHARGER

PUMP
SPEED
RESISTOR 2ND

3ND
•
MOTOR

NOTES:
1. SYMBOLS: F =FORWARD CONTACTOR
R =REVERSE CONTACTOR
B = DYNAMIC BRAKE
P = PUMP SOLENOID
=
L REMOTE LOWERING (OPT)
HM = HOUR METER (OPT)
=
Dl DISCHARGE INDICATOR (OPT)
2ND = 2ND SPEED CONTACTOR
=
3RD 3RD SPEED CONTACTOR
2. OPTIONAL CIRCUITS DASHED. 'X' DENOTES CONNECTION BROKEN WITH OPT. CIRCUIT.
3. SEE WIRING DIAGRAM 504155.

•
R5433

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

PDM0495

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• CONTROL HEAD - - - -

-- --, REVERSING
F
LIFT SAFETY
•
...I
A
R

2ND

J
3RD

y. '("'
''
• •
BRAKE HORN
'R~
...:1-L-O_W_E_R____ - ··-- - •• - ••

I
I

' ' I
-----1----1
I

•
L - - -- -1---- _ _ _ ..J I
.----
- - - - - - - - - - . . , ' r---
1I rw-·-..
I I

I t..:-,-~

z
a:
'
, ...L ' ' ,.,'
B I IHMI R F
0
I 'r'' 'r'
I I
I
jHIGH
1 s~o
I
I
I
I
I

R5434

• PDM0495
Figure 4-1. Electrical Wiring Diagram (Sheet 2)

4-7

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NOTES

4-8 PDM0495
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•
SECTION 5
STEERING ARM AND CONTROL HEADS SERVICING.

1. SEE SUPPLEMENT 220 FOR TRANSISTOR 5-2. COLD CONDITIONING.

TRUCKS SERIAL NUMBER The cold conditioning version of the truck differs from
334631 AND HIGHER. the standard model where necessary to improve per-
2. SEE SUPPLEMENT 207 FOR TRANSISTOR formance in cold temperatures. Heating resistors are
TRUCKS SERIAL NUMBER provided for the control head switches, and cold resis-
333620 TO 334630. tant versions of other switches are used. Special cold
temperature lubricants are also necessary for this
5-1. GENERAL. application.
The following procedures cover adjustments, replace- Figure 5-1 is an electrical schematic diagram of the cold
ment, and repair of the steering arm, control head, and conditioning circuit. Location of electrical parts in the
related assemblies and components. The procedures control head and resistor wiring of cold conditioning
are independent of each other unless specifically equipment is illustrated in Rgure 5-2.
referenced.

1.SEE SUPPLEMENT 220 FOR TRANSISTOR

SPEED CONTROL TRUCKS SERIAL
NUMBER 334631 AND HIGHER.
2.SEE SUPPLEMENT 207 FOR TRANSISTOR

•
SPEED CONTROL TRUCKS SERIAL
+ WIRE 15
NUMBER 333620 TO 334630.

THERMAL.
CUTOFF
SWiltH

ca.D-CONOITIONING
RESISTORS

- WIRE 16
12 VOLT
RS418

Figure 5-1. Schematic of Cold

Conditioning Circuit
RS419

Figure 5-2. Location of Resistors and

Thermal Cutout Switch

• PDM0495 5-1

https://forklift-manuals.jimdofree.com
 •
CAUTION: Cold conditioning heating resistors con-
sume power when energized, whether
truck is used or not. To avoid power waste
during lengthy storage periods, remove BELLY BUTTON
truck from cold temperatures. SUPPORT
NG
5-3. BELLY-BUTTON SWITCH ADJUSTMENT.

NOTE: All electrical connections should be tagged

with identifying labels before disconnecting.
1. Disconnect battery.

CAUTION: While removing the belly-button casting,

two springs (needed for reassembly) will
fall free.
2. Being careful to catch and retain the belly-button
springs (25, Figure 5-4) that may fall from the
control head (41) as the belly-button casting (42) is
removed, drive out the roll pins (11) that secure the
belly-button casting. Drive the roll pin from left to
right. The roll pin is only tight on the left side.

CAUTION: A misaligned switch may actuate (click)

early or late in travel, or fail to operate. R960
L---------------------------------------------------------------------------------~
WARNING: Test switch in an open area to avoid being Figure 5-3. Belly-Button Switch Adjustment
accidentally pinned.

~·
5-4. CONTROL HEAD SWITCH REPLACEMENT.
3. Bend actuator lever of belly-button switch (Fig-
ure 5-3) to adjust gap so that switch clicks half way NOTE: Refer to paragraph 5-5 for speed control switch
through travel of casting. replacement.
4. Reinstall casting, making certain all parts are back
NOTE: For access to belly-button switch, see para-
in place. graph 5-3. For access to other switches on
5. Check operation of the belly-button switch by press- control head, the top cover (15, 16, or 17,
ing the belly-button casting while listening for the Figure 5-5) and/or switch plate (18) must be
"click" that indicates that the switch has actuated. removed.

NOTE: The click should be heard when the belly-but- NOTE: All electrical connections should be tagged
ton casting has moved about 50 per cent of with identifying labels before disconnecting.
its normal travel distance. If the click is heard
at the beginning of travel, the switch may 1. Disconnect battery.
actuate at inappropriate times. If the click is
2. If necessary to gain access to defective belly-button
heard near the end of travel, the switch could
switch, remove belly-button casting (42, Figure 5-4)
be unreliable and may not actuate in some
by performing step 2 in paragraph 5-3.
instances.
3. Remove top cover (15, 16, or 17, Figure 5-5) by
6. Repeat steps 2 through 5 until pressing the belly- removing four screws (14).
button casting actuates the switch properly.
4. Remove switch plate (18) by removing four screws
7. Reconnect battery and electrical connections. (15 and 16, Figure 5-4) on top and bottom of control
handle (41).
WARNING: Testing of belly-button switch in operation
should be limited to areas clear of obsta- 5. Replace belly-button switch (3), speed control
cles against which an operator could be switches (4), horn switch (4, Rgure 5-5}, or lift,
pinned. Use first speed, reverse. lower and dynamic brake switches (3).

5-2 PDM0495

https://forklift-manuals.jimdofree.com
• 1.SEE SUPPLEMENT 220 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL
NUMBER 334631 AND HIGHER
2.SEE SUPPLEMENT 207 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL
NUMBER 333620 TO 334630

19--f

• 42
25~~//

0
v /
3~
2

(A "7 /

0 ~ 37
II

R3837

Figure 5-4. Control Head Assembly

• PDM0495 5-3

https://forklift-manuals.jimdofree.com
 1.SEE SUPPLEMENT 220 FOR TRANSISTOR 2.SEE SUPPLEMENT 207 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL SPEED CONTROL TRUCKS SERIAL
NUMBER 334631 AND HIGHER NUMBER 333620 TO 334630

PDM WITH LIFT ONLY PDM WITH HORN AND BRAKE

505050-02 {OPTION) 505050-01, 02 & 03 (STANDARD)

R5215

PDM WITH LIFT AND LOWER

505050-03 (OPTION)

R5217

PDM 505050-1

~·
(STANDARD)

R5216 R5211

Figure 5-5. Control Head Pushbutton Switches

NOTE: If the belly-button switch is replaced, adjust it 5-5. SPEED CONTROL SWITCH RETURN SPRING
in accordance with paragraph 5-3 before using REPLACEMENT.
truck. 1. Disconnect battery.

6. Replace switch plate (18) and secure with four 2. Remove four screws (17, Figure 5-6) securing con-
screws (15 and 16, Figure 5-4) on top and bottom trol head to steering arm.
of control handle (41).
3. Disconnect connector (25).
7. Replace top cover (15, 16, or 17, Figure 5-5) and 4. Remove four screws (14, Figure 5-5) and top cover
secure with four screws (14). (15, 16 or 17).

8. Reconnect battery. 5. Disconnect speed control switches (4, Figure 5-4).

5-4 PDM0495

https://forklift-manuals.jimdofree.com
•
6. Remove four screws (17) securing handle guard 1. Disconnect the battery.
(36) to control head.
2. Hold the steering arm (12, Figure 5-6) in the upright
7. Remove two socket head screws (18) and caps position and make sure the arm cannot fall.
(29) from handle guard (36).
3. Insert a 5/16 allen wrench through hole in bottom
8. Remove handle guard with two brackets (33 and
of steering arm and loosen screw (15). The spring
39) and speed control switches (4) attached.
tube (1) will rotate counterclockwise when screw is
9. Remove roll pin (1 0) from right hand handle grip loosened.
(31).
10. Remove right hand handle grip from shaft (28).
4. With a pair of vise grip pliers, grip the flat surfaces
of the spring tube assembly (1) and rotate clock-
11. Remove set screw (22) from right hand control lever wise 180 degrees.
(40).
12. Remove right hand control lever from tube (34). 5. Hold spring tube assembly in rotated position and
tighten screw (15) to secure.
13. Observing through top cover opening, slide shaft
(28) with tube (34) out left hand side of control head 6. Check the spring action by lowering the steering
just enough to clear return spring (24). arm and returning it to the upright position two or
14. Disengage return spring from spiral pin (12) and three times.
remove return spring. 7. If necessary, repeat steps 2 through 6, increasing
15. Place new return spring in position, engage with or decreasing amount of rotation of the spring tube
spiral pin, and slide shaft (28) with tube (34) back assembly until steering arm returns gently to full
through return spring and out right hand side of upright position.
control head.
8. Reconnect battery.
16. Install right hand control lever (40) onto tube (34),
and secure with set screw (22).
5-7. STEERING ARM RETURN SPRING
17. Install right hand handle grip (31) onto shaft (28),

•
REPLACEMENT.
align roll pin hole in handle grip with roll pin hole in
shaft, and install roll pin (10). NOTE: The steering arm return spring is replaced
18. Install handle guard (36), with two brackets (33 and while the steering arm is in the upright position.
39) and switches (4) attached, and secure with two
caps (29) and screws (18). 1. Disconnect battery.
19. Install four screws (17) through handle guard and NOTE: The steering arm has a tendency to fall down-
into control head. ward when the tension on the return spring is
20. Reconnect speed control switches (4). released.
21. Install top cover (15, 16 or 17, Figure 5-5) with four
screws (14). 2. Hold steering arm (12, Figure 5-6) in upright posi-
tion and make sure the arm cannot fall.
22. Reconnect connector (25, Figure 5-6).
23. Install control head onto steering arm with four 3. Insert a 5/16 allen wrench through hole in bottom
socket head screws (17). of steering arm and loosen screw (15).
24. Reconnect battery. CAUTION: Unless properly supported, steering arm
will drop out of pivot cap when spring tube
5-6. STEERING ARM RETURN SPRING is removed.
ADJUSTMENT.
The tension on the steering arm return spring should 4. Put a block under steering arm at pivot cap.
allow the steering arm to return gently to the upright 5. With a piece of chalk or crayon, draw a straight line
position. Excessive tension on the steering arm return from center of spring tube assembly (1) into pivot
spring will cause the steering arm to snap up and may cap (3), marking radial position of tube, to facilitate
cause damage to the electrical cable, brake linkage, or
reinstallation.
the spring itself. If the steering arm does not return fully,
check for binding in the brake linkage or wiring harness 6. With a pair of vise-grip pliers, grip the flat surfaces

•
before making any adjustments. If they do not bind, refer of spring tube assembly (1), and slowly pull it free
to Figure 5-6 and proceed as follows to adjust the from the steering arm, pivot cap and tube clamp
steering arm return spring tension. (10).

PDM0495 5-5

https://forklift-manuals.jimdofree.com
 ~·
SEE SUPPLEMENT 228 FOR HANDLE RETURN SPRING
TRANSISTOR SPEED KIT 901325 CONTAINS
CONTROL TRUCKS QTY
1
1

o--21 1
1
2
2
1
1
3

18
25
~·
I

R5385
16)A :
15 )12
24
USED ON TRUCKS
SERIAL NUMBER
333620 TO 346721,

22'1 346723 TO 346750,

346752 TO 346926,

21"© 346928 TO 346934

AND346936

•
R5384

Figure 5-6 Steering Arm and Pivot Cap

PDM0495

https://forklift-manuals.jimdofree.com
•
NOTE: Steering arm return spring (2) will remain in- 6. Remove pivot cap (3) and spacer (1, Figure 5-7).
side the spring tube assembly (1 ). 7. Position a chain hoist above the pivot tube.
7. Remove steering arm return spring (2) from spring 8. Connect chain to pivot tube as follows:
tube assembly (1 ). If spring is severely jammed and a. For trucks serial numbers 333620 to 346721,
will not come loose, punch and drive the 1/4-inch 346723 to 346750, 346752 to 346926,
diameter roll pin {14) into the tube. Save pin for reuse. 346928 to 346934, and 346936, use the two
Remove the spring. Tap roll pin back into place. pivot cap cover screws (22) as a means of at-
8. Lubricate the ends and outer surface of the new tachment for the chain hoist. Secure the
steering arm return spring (2) with a lithium base chain hoist to the pivot tube.
general purpose grease. b. For trucks serial numbers 346722, 346751,
9. Insert spring into spring tube assembly and press 346927,346935,346937 and higher, use
in, making sure that one spring loop eye fits over tool kit part number 907151. Position
the 3/8-inch roll pin (13) at the closed end of the spacer, Rgure 5-7, inside the pivot tube. In-
spring tube assembly. sert the pin through the support tube and se-
cure with the cotter pin. Attach chain hoist to
10. Slide spring tube assembly into pivot cap (3) and
the spacer.
steering arm (12) through tube clamp (1 0) and
through loop of electrical cable. 9. Remove cotter pin (1 0, Figure 5-8) and pull out
spring support pin (12).
11. Align radial position of spring tube assembly in
accordance with line drawn in step 5. Slowly rotate
spring tube assembly a few degrees each way until TOOL KIT
the steering arm return spring snaps into place over 907151 CONTAINS ~SPACER
spring pins (6 and 7) then tighten screw (15). 1 COTTER PIN

~I
12. Apply engine lubricating oil (No. 2) to the steering 1 PIN

• arm elbow. 1 SPACER I I 1

I

13. Remove block from under steering arm.

14. Adjust tension on steering arm return spring as
explained in paragraph 5-6.
15. Reconnect battery.

5-8. PIVOT TUBE REPLACEMENT.

NOTE: All electrical connections and cabling should

be tagged with identifying labels before discon-
necting.
R5432
NOTE: A chain hoist is required for this procedure. It Figure 5-7. Pivot Tube Removal Tool
should be in position above the pivot tube
before disassembly. 10. Remove the support from under the pivot tube and
remove the pivot tube from the bottom of the truck.
1 . Remove the transmission as described in Section
7. 11. Disconnect the chain from the pivot tube and re-
move spring support (11), spring (13), and thrust
2. Position a support under pivot tube (7, Rgure 5-7).
bearing (6).
3 On trucks serial number 333620 to 346721 , 346723 12. Remove three screws (2) securing bushing (3).
to 346750, 346752 to 346926, 346928 to 346934,
and 346936, remove two socket head screws (22, 13. Remove lower pivot bushing (3).
Rgure 5-6) securing pivot cap cover. 14. Remove upper pivot bushing (5).

•
4. Remove pivot cap cover (21 ). 15. Inspect the bearing (6) for wear. If worn, replace
5. Remove electrical control cable, steering arm and with new bearing.
control head from pivot tube assembly. 16. Discard the two old bushings (3 and 5).

PDM0495 5-7

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NOTE: When installing the new parts, refer to Rgure 8. Tape the disconnected end of the old cable to the
5-8 to be sure they are positioned on the pivot terminal end of the new cable.
tube in the proper order.
NOTE: The dead-man switch is on the brake linkage.
17. Install bushing (3) with screws (2). The wire connected to pin number 3 on the
18. Install bushing (5). terminal board (9) is a wire that comes from the
dead-man switch. Cable wire number 3 is con-
19. Route support chain through pivot weldment and
nected to the other lead on the dead-man
through thrust bearing (6), spring (13) and spring
switch.
support (11 ).
20. Attach hoist chain to pivot tube as described in step 9. Remove base access cover, and disconnect termi-
8. nal end of old cable from transmission terminal
board (9) and cable wire number 3 from deadman
21. Install the pivot tube (7) through the bottom of the switch lead.
truck and position a support under pivot tube.
10. Draw new cable into pivot tube by pulling old cable
22. Attach spring support (11) to pivot tube with spring through the base access opening.
support pin (12).
NOTE: The cable leads are numbered consecutively.
23. Secure spring support pin (12) with cotter pin (1 0).
24. Remove hoist chain and the two pivot cap cover 11. Untape the old cable from the new cable and con-
screws or pivot tube tool as applicable. nect the new cable terminals sequentially, starting
with pin 1 on the transmission terminal board (9).
25. Install spacer (1) on pivot tube (7).
12. Cut the terminal off of cable wire number 3 and
CAUTION: Be sure to observe cable routing and po- connect this wire to the wire from the deadman
sitioning when reinstalling electrical con- switch.
trol cable to prevent cable damage. 13. Check that the other wire from the deadman switch
is connected to terminal 3.
26. Reinstall steering arm onto pivot tube, being careful
not to damage electrical control cable while routing 14. Route connector (8) end of cable under spring tube
it through the pivot tube. (See Figure 5-9). assembly (3) and out the opening at the elbow.
15. Eliminate cable slack in pivot tube (1 0), then secure
27. Install pivot cap cover.
cable with cable clamp (1).
28. Install the transmission as described in Section 7.
CAUTION: Improper cable loop adjustment while per-
5-9. ELECTRICAL CONTROL CABLE forming the following step will damage the
REPLACEMENT. cable. If too tight, the cable will tear when
the steering arm is in the up position.lftoo
1. Disconnect battery. loose, the cable will buckle or be pinched
NOTE: When removing control head in the following when the steering arm is in the down
step, be sure to hold it in place until cable is position.
disconnected. 16. Loop cable around spring tube assembly (3) as
2. Remove four screws (7, Rgure 5-9) that secure illustrated and push connector (8) end of cable
control head to steering arm. through steering arm.
3. Disconnect connector (8), and set aside control 17. Pull the cable until the cable is wrapped firmly
head. around the spring tube assembly (3). Slack off
approximately 1/2 inch and secure the cable in this
4. Use Amp Extraction Tool part number 900750 to position with cable clamp (2).
push out and disconnect wire pins from connector
(8). 18. Work steering arm up and down a few times to
assure that the electrical control cable is not
5. Remove cable clamps (1, 2) and loosen loop of binding.
cable that surrounds the spring tube assembly (3).
19. Plug connector (8) into the control head receptacle.
6. Remove pivot cap cover (6).
7. Pull disconnected end of old cable through steering 20. Reinstall the control head assembly, pivot cap
arm and pivot cap, then up through pivot cap cover cover, and base access cover.
opening. 21. Reconnect battery.

PDM0495

https://forklift-manuals.jimdofree.com
 6--o
•

.. ..I

... , " ' I

4--o:
5~:
~I;'
.... ...

613--110--- PIVOT
11--tai( TUBE

• 12y~
I

:~ ... ...
I'
...

1. CABLE CLAMP
2. CABLE CLAMP
3. SPRING TUBE ASSEMBLY
4. ELECTRICAL CONTROL CABLE
5. PIVOTCAP
6. PIVOT CAP COVER
7. CAP SCREWS
8. FEMALE CONNECTOR
9. TERMINAL BOARD
10. PIVOT TUBE
11. TRANSMISSION HOUSING

•
R5387 R962, R963

Figure 5-8. Pivot Tube Assembly Figure 5-9. Electrical Control Cable Replacement

PDM0495 5-9

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 NOTES

~·

5-10 PDM0495
•
https://forklift-manuals.jimdofree.com
•
SECTION 6
BRAKE SERVICING

6-1. GENERAL 6-2.1. Adjustment For Truck Serial Numbers 333761

And Higher.
There are two different brake systems: one is used on
truck serial numbers 333761 and higher, and the other 1 . Disconnect battery connections.
is used on truck serial numbers 333620 to 333761. The
adjustment and parts replacement procedures for these 2. Securely block the truck to prevent slipping, then
two systems are different and are described separately. jack up the truck so the drive wheel is off the
ground.
6-2. ADJUSTMENT
3. Remove base access cover.
If the mechanical brake does not begin to hold when the
steering arm is raised or lowered into the lightly shaded 4. Secure steering arm assembly in a position that is
area in Figure 6-1, proceed as follows: in either lightly shaded area shown in Figure 6-1.

CONTROLS ARE ENERGIZED.

MECHANICAL BRAKE
STAATS TO ENGAGE.

• CONTROLS ARE
DE.£NEAGIZED.
MECHANICAL BRAKE
IS ENGAGED.

CONTROLS ARE
ENERGIZED.
MECHANICAL BRAKE
STARTS TO ENGAGE.

SIDE VIEW

R3629

Figure 6-1. Brake Engage/Disengage

• PDM0495 6-1

https://forklift-manuals.jimdofree.com
 •
5. Remove the cotter pin (1, Figure 6-2), and pin (2) mounting bracket, then sliding the switch in or out
to disconnect the clevis (3) from the lever assembly. in the adjustment slots, and tightening the screws.
6. Loosen the lock nut (4). 17. Make sure that applying the brake activates the
switch but does not fully depress the switch
plunger. If necessary, repeat steps 15 and 16 until
TRUCK SERIAL the switch is properly positioned.
NUMBERS 333761,
18. Lower the truck and install the base access cover.
AND HIGHER
19. Reconnect battery connections.
20. In an area free of obstructions, accelerate the truck
and apply the brake. Check for proper operation in
both forward and reverse.

6-2.2. Adjustment For Truck Serial Numbers

333620 to 333760.
1. Disconnect battery connections.
2. Securely block the truck to prevent slipping; then
jack up the truck so the drive wheel is off the
ground.
3. Remove base access cover.
4. Secure steering arm assembly in a position that is
in either lightly shaded area shown in Figure 6-1.
5. Spin drive wheel by hand and position weldment
R3296
tube (1, Figure 6-3) by adjusting nuts (2) until you
feel a noticeable drag.
Figure 6-2. Adjustment For Truck Serial
Numbers 333761 and Higher.
TRUCK SERIAL NUMBERS
333620 TO 333760
7. Turn the clevis (3) to adjust the brake.
8. Connect the clevis (3) to the lever assembly with pin
{2), but do not insert the cotter pin (1) at this time.
9. Turn the brake disc by hand to check brake adjust-
ment. If there is noticeable drag, go to step 12. If
there is no drag, go to step 10.
10. Disconnect the clevis (3).
11. Repeat steps 7 through 9 until adjustment is correct.
12. Secure the steering arm in drive position and spin
the drive wheel to make sure there is no drag. If
there is any drag, carefully readjust only enough to
eliminate drag in the drive position.
13. Tighten the lock nut (4) and secure the pin (2) with
the cotter pin (1).
14. Remove the restrictions from the steering ann and R359
let the ann return to the upright position.
Figure 6-3. Adjustment For Truck Serial
15. Check that the brake lever has activated the dead- Numbers 333620 to 333760
man brake switch (42, Figure 6-4) and open the
control circuits. If the switch is not activated, go to
step 16. If it is activated, go to step 18. 6. Tighten nuts (2) without changing position of weld-
16. Adjust the position of the dead-man switch by loos- menttube.
ening the screws (41) attaching the switch to the

6-2 PDM0495

https://forklift-manuals.jimdofree.com
•
7. Secure the steering arm in drive position and spin 11. Make sure that applying the brake activates the
the drive wheel by hand to be sure there is no drag; switch but does not fully depress the switch
readjust if necessary. plunger. If necessary, repeat steps 9 and 10 until
8. Remove the restrictions from the steering arm and the switch is properly positioned.
let the arm return to the upright position. 12. Lower the truck and reinstall base access cover.
9. Check that the brake lever has activated the dead- 13. Reconnect battery connections.
man brake switch (34, Figure 6-5) and opened the
control circuits. If the switch is not activated, go to 6-3. REPLACEMENT OF DISC BRAKE PARTS
step 10. If it is activated, go to step 12.
10. Adjust the position of the dead-man switch by loos- 6-3.1. Parts Replacement For Truck Serial Numbers
ening the screws (35) attaching the switch to the 333761 And Higher.
mounting bracket, then sliding the switch in or out in 1. Disconnect battery connections.
the adjustment slots, and tightening the screws.
2. Block the wheels to prevent the truck from rolling.

TRUCK SERIAL NUMBER

333761 AND HIGHER

HORN REF 42
A
•
_..__25 41
-~24 _ij!}~
--

R3297

• PDM0495
Figure 6-4. Parts Replacement for Truck Serial Numbers 333761 and Higher

6-3

https://forklift-manuals.jimdofree.com
 3. Position the steering arm to the left as far as possi- 3. Position steering arm to the left as far as possible

~·
ble, and secure the steering arm down from its park and secure the steering arm down from its park
position so that the mechanical brake is disen- position so that the brake is disengaged.
gaged. 4. Remove base access cover.
4. Remove base access cover.
NOTE: The brake pads may fall free during the next
5. Remove the cotter pin (2, Figure 6-4) and link pin step.
(7), then swing the clevis {13) up out of the way.
5. Remove two bolts (25, Figure 6-5) and nuts (26) to
6. Remove two nuts (28) and lockwasher (29). release brake pads (24).
7. Carefully pull the bolts (30) just enough to clear the 6. If brake pads don't fall free, slide brake pads out
mounting plate weldment (17) while you hold to- from end of clamp (22).
gether the remaining parts of the disc brake assem-
7. Insert replacement brake pads in clamp assembly,
bly (27), then remove the assembly.
one pad on each side of disc (31) with linings
8. Remove the bolts (30), spacers (31), springs (32), towards the disc, and secure pads and clamp with
and brake pad (33). two bolts (25) and nuts (26). Be sure spring (37) is
9. Remove the retaining C-ring (34), washer (35), installed between pads.
spring (36), bracket (38), lever (39), and washer 8. Release steering arm.
(40) from the brake pad (37). 9. Refer to paragraph 6-2 and adjust brake.
10. Discard the springs (32 and 36) and brake pads (33 1o. Reconnect battery connections.
and 37). Replace them with new parts. ·
6-3.2.2. Brake Lever.
11. Assemble the washer (40), lever (39), bracket (38),
spring (36), washer (35), and C-ring (34) to the 1 . Disconnect battery.
brake pad (37). 2. Block the wheels to prevent the truck from rolling.
12. Assemble the brake pad (33), spacers (31), and 3. Remove base access cover.

~·
springs (32) to the two bolts {30). 4. Position steering arm to the left as far as possible
13. Slip the parts assembled in step 11 onto the mount- and secure the steering arm down from its park
ing plate weldment {17) and hold them so the bolt position so that the mechanical brake is disen-
holes are aligned. gaged.

14. Insert the bolts (30) through pad (37) and bracket NOTE: The brake lever (23, Figure 6-5) has a pin that
(17), so the threaded portion of the bolts passes fits into one of two slots on the inside of the
completely through. clamp assembly.
15. Assemble the two lock washers (29) and nuts (28) 5. Check position of lever inside the clamp assembly
to the bolts (30). so that you will be sure to place brake lever pin in
16. Engage the clevis {13) with the lever (39), then correct slot during reassembly.
insert the pin (7) and secure it with the cotter pin 6. Release brake lever (23) from weldment tube (20)
(2). by removing cotter pin (19) from weldment tube
17. Remove the restrictions from the steering arm. stub.

18. Adjust the brake as described in paragraph 6-2. NOTE: The brake pads (24) and springs (37) may fall
free during the next step.
19. Install the base access cover.
20. Reconnect battery connections. 7. Remove two bolts (25) and nuts (26) to release
brake clamp (22) from mounting plate (27).
6-3.2. Parts Replacement For Truck Serial Numbers 8. If brake pads did not fall free, slide the brake pads
333620 to 333760. (24) out from end of clamp and slide the brake lever
(23) out through the brake lever access hole lo-
6-3.2.1. Disc Brake Pad Replacement.
cated on the opposite side of the clamp.
1. Disconnect battery connections. 9. Check that replacement brake lever {23) has pin
2. Block the wheels to prevent the truck from rolling. tightly secured.

~·
PDM0495

https://forklift-manuals.jimdofree.com
• TRUCK SERIAL NUMBERS
333620 TO 333760

',,' 5
BRAKE PAD KIT
PART NUMBER
800182 CONTAINS
ITEM
22
23
QTY
1
1
24 2
25 2
26 2
37 2
3
12

35

3
I

• Z1

31
R357

Figure 6-5. Parts Replacement for Truck Serial Numbers 333620 to 333760

10. Slide the brake lever (23} in through the brake lever 15. Reconnect battery connections.
access hole located on the opposite side of the
clamp and align the brake lever so that the pin is in 6-3.3. Replacement of Brake Disc.
the proper pin slot.
11. Slide clamp (22) on mounting plate (27) so that 6-3.3.1. Disc Replacement For Truck Serial Numbers
mounting plate is at lever side of clamp, reinstall 333761 and Higher.
brake pads (24), one pad on each side of disc (31)
with linings toward the disc, and check that pin in 1. Disconnect the battery.
lever is in proper slot of the clamp. 2. Block the wheels to prevent the truck from rolling.
12. Secure clamp to mounting plate with two bolts (25)
3. Remove the base access cover.
and nuts (26). Be sure springs (37) are installed.
4. Position the steering arm to the left as far as possi-

•
13. Insert stub of weldment tube (20) up through hole
in brake lever (23) and secure with cotter pin (19) . ble, and secure the steering arm down from its park
position so that the mechanical brake is disen-
14. Adjust brake as described in paragraph 6-2. gaged.

PDM0495 6-5

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 •
5. Remove the cotter pin (2, Figure 6-4) and pin (7), 6-3.3.2. Disc Replacement For Truck Serial Numbers
then swing the clevis (13) up out of the way. 333620 to 333760.
6. Remove the two nuts (28) and lock washers (29). 1. Disconnect the battery.
7. Carefully pull the bolts (30) just enough to clear the 2. Block the wheels to prevent the truck from rolling.
mounting plate weldment (17) while you hold to-
getherthe remaining parts of the disc brake assem- 3. Position the steering arm to the left as far possible
bly (27), then remove the assembly. and secure the steering arm down from its park
position so that the mechanical brake is disen-
8. Remove the nut (21) and lock washer (20). gaged.
9. Remove the disc assembly (19). 4. Remove base access cover.
10. Remove the key (18).
5. Remove two bolts (25, Figure 6-5) and nuts (26) to
11. Install new disc assembly with key(18), lock washer release brake pads (24).
(20) and nut (21).
6. If brake pads don't fall free, slide brake pads out .
12. Assemble the brake pad (33), springs (32), and from end of clamp (22).
spacers (31) to the two bolts (30).
7. Remove nut (33) and lock washer (32).
13. Slip brake pad (37) with attached parts onto the
mounting plate weldment (17) and hold it so the bolt 8. Remove the disc assembly (31).
holes are aligned. 9. Remove key (30).
14. Insert the bolts (30) through the pad (37) and 10. Install new disc assembly with key (30), lock
bracket (17), so the threaded portion of the bolts washer (32) and nut (33).
passes completely through.
11. Insert brake pads in clamp assembly; one pad on
15. Assemble the two lock washers (29) and nuts (28) each side of disc (31) with linings toward the disc,
to the bolts (30). and secure pads and clamp with two bolts (25) and
16. Engage the clevis (13) with the lever (39), then insert nuts (26). Be sure springs (37) are installed be-
the pin (7) and secure it with the cotter pin (2). tween pads.
17. Remove the restrictions from the steering arm. 12. Remove the restrictions from the steering arm.
18. Adjust brake as described in paragraph 6-2. 13. Adjust brake as described in paragraph 6-2.
19. Reconnect the battery. 14. Reconnect the battery.

PDM0495

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•
SECTION 7
TRANSMISSION, DRIVE WHEEL CASTER WHEEL AND LOAD WHEEL SERVICING

7-1. TRANSMISSION REMOVAL AND 7. Disconnect the mechanical brake by removing cot-
DISASSEMBLY ter pin (1, Figure 7-2) clevis pin (2) that secures the
rod clevis to the lower lever assembly (3).
1 . Disconnect battery.
2. Securely block load wheels. Remove base access NOTE: Transmission oil capacity is 3 pints.
cover.
8. Remove the transmission drain plug (5, Figure 7-1)
3. Disconnect the wires to the dead man switch. and drain the transmission oil.
4. Disconnect the wire to the hom. 9. Position the drive assembly to access the two
screws (24) and washers (18) which secure the
5. If the cable leads connected to the terminal block
motor to the transmission housing and remove the
(42, Rgure 7-1) are not clearly labeled, label them
screws and washers.
from right to left beginning with 1 and then discon-
nect the cable leads from the terminal board. 10. Reposition the drive assembly to allow the motor to
be pulled out through the access opening.
6. Make sure the four cables to the drive motor (38)
are proper1y labeled A1, A2, F1, and F2 and then 11. Disconnect brake rod (4, Figure 7-2) from lower
disconnect the cable from the drive motor. lever assembly (3).

•
R5388

Figure 7-1. Transmission Assembly

PDM0495 7-1

https://forklift-manuals.jimdofree.com
12. Remove the four screws (5) and washers (6) that 7. Reverse the above procedures to install new drive

~·
secure the transmission (7) to the pivot tube weld- wheel. Torque screws (36) to 115-125 ft.-lbs.
ment (8).
13. Remove the transmission and drive wheel (9) from 7-3. CASTER WHEELS.
the truck by raising the rear of the lift truck with jacks The caster wheel assembly 901610 is installed as origi-
or other suitable means and sliding the assembly nal equipment on trucks serial number 344859 and
out from under the truck. higher. Caster assembly 901100 is used on trucks with
14. Remove the four hex head cap screws (22, Fig- lower serial numbers. Parts are available for servicing
ure 7-1) and lock washers (23), bearing cover (21) this older caster but the complete assembly is not
and gasket (20). available. Use the new caster for complete assembly
replacement.
15. Remove bearing spacer (15).
16. Remove seven screws (19), two screws (25), and 7-3.1 Caster Wheel Assembly 901610.
lock washers (18); pry off transmission cover (17) 1. Unload the truck and block the drive wheel and load
and pull off cover gasket (16). wheels.
17. Remove ball bearing (14) and pinion spacer (13). 2. Disconnect the battery.
18. Remove intermediate gear (12) and square key 3. Raise the rear of the lift truck with a jack or another
(10). lift truck and place supporting boards or steel bars
19. Remove spur pinion (11). under the body approximately six inches in front of
the caster wheel that is to be changed.
20. Remove locknut (8) and lock washer (7).
4. Lower the lift truck onto the support.
21. Remove drive wheel and axle shaft (1) to free gear
(6), roller bearing cones (3) and cups (4), and oil 5. Remove the caster wheel axle and nut (2, Figure
seal (2). 7-3) to remove the caster wheel, and spacers (3
and 4).

~·
22. Remove ball bearing (9).
6. Reassemble the caster wheel assembly, and spac-
23. Refer to the disassembly instruction as a guide, and
ers (3 and 4) with caster axle and nut (2).
reverse the individual procedures of steps 20
through 1 to reassemble and reinstall the transmis- 7. Check wheel for free movement.
sion. 8. When replacing complete caster assembly be sure
NOTE: When reassembling, be sure to replace the to install spacers (1 ).
gasket and reinstall the magnetic drain plug
before refilling the transmission with transmis- 7-3.2 Caster Wheels Assembly 901100.
sion oil. Transmission oil capacity is 3 pints. NOTE: When replacing complete assembly replace
w~hpartnumber90161Q
24. Fill the transmission to fill plug level with EP SAE
80W-90 automotive transmission oil. 1. Unload the truck and block the drive wheel and load
wheels.
7-2. DRIVE WHEEL REPLACEMENT
2. Disconnect the battery.
1. Disconnect battery.
3. Raise the rear of the lift truck with a jack or another
2. Securely block the load wheels to prevent the truck lift truck and place supporting boards or steel bars
from moving. under the body approximately six inches in front of
3. Remove base access cover. the caster wheel that is to be changed.

4. Use a jack to raise the rear of the lift truck so that 4. Lower the lift truck onto the support.
the drive wheel clears the ground. 5. Remove the caster wheel axle and nut (1, Figure
5. Lower the truck on blocks, making certain the drive 7-4) to remove the caster wheel, bearings, and
wheel is still clear of the ground. bushing (2 through 4).
6. Clean bushing and check for defects.
6. Remove the five retaining screws (36, Figure 7-1)
and lock washers (35) that secure the drive wheel
to the axle shaft and then pry off the wheel.
7. Apply lithium base general purpose grease to the
bushing.
fl
7-2 PDM0495

https://forklift-manuals.jimdofree.com
• TRUCK SERIAL NUMBERS 333761 AND HIGHER

I ALL TRUCKS

• 9

I TRUCK SERIAL NUMBERS 333620 TO 333760 I

/
,, /

,"" 2--~
/
/
c',/

R3943

• PDM0495
Figure 7-2. Transmission Removal

7-3

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 ~·

R5355 5 R5393

Figure 7-3. Caster Wheel Assembly 901610 Figure 7-4. Caster Wheel Assembly 901100

8. Reassemble the caster wheel assembly, bushing, 4. Lower the lift truck onto the support.
and bearings (2 through 4) with caster axle and nut
(1).
9. Check wheel for free movement.
5. Remove the snap ring (5, Figure 7-5), roll pin (6),
and remove the load wheel axle (4). The load wheel ~·
(1), bearing (2), spacers (3), and seal washers (7)
(for 4-inch load wheels only) will fall out.
7-4. LOAD WHEELS.
NOTE: 3-inch load wheels should be repacked with
NOTE: Standard Model PDM-30 lift trucks have 4-inch grease when required. 4-inch load wheels
tandem load wheels. Replace tandem wheels have grease fittings.
as a pair.
6. Check that bearing on replacement wheel turns
1. Unload the truck and block the drive wheel.
freely and smoothly.
2. Disconnect battery.
7. Reassemble the load wheel (1 ), bearings (2), spac-
3. Raise the front of the lift truck with a jack or another ers (3) and seal washers (7) (for 4-inch load wheels
lift truck and place supporting boards or steel bars only) on the axle (1) and secure with roll pin (6) and
under the straddle leg immediately in back of the snap ring (5).
wheel housing to hold wheel at least 1 inch off of
floor. 8. Check wheel for free rotation.

~·
7-4 PDM0495

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•

R393 4-in. Load Wheel

•
R394 3-in. Load Wheel
.
F1gure 7- 5· Load Wheels

• PDM0495 7-5

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 NOTES

~·
7~ PDM0495

https://forklift-manuals.jimdofree.com
•
SECTION 8
ELEVATION SYSTEM SERVICING

8-1. GENERAL 6. Remove screws (7), lockwashers (2), wear spacers

(17} and clamp bar (1 0) and lift the ram head (20)
The elevation system includes the mast, lift chains, lift off the lift cylinder.
cylinder, and ram head.
7. The ram head can now be repaired or replace as
required.
8-2. RAM HEAD REPLACEMENT (Non-Telescopic
and Telescopic Trucks} 8. Reinstall ram head in reverse order of removal.
9. Adjust lift chains as described in paragraph 8-4.
8-2.1. Non-telescopic Trucks
8-3. YOKE SHEAVE REPLACEMENT (Full Free Lift
The ram head may be replaced as an assembly com-
Trucks}
plete with sheaves; or any part in the assembly may be
replaced. WARNING: Before attempting any service make cer-
tain power is disconnected.
WARNING: Before attempting any service make cer-
tain power is disconnected. 1. Lower the lift carriage fully.
1 . Lower the lift carriage fully. 2. Disconnect the battery.
3. Slacken the lift chains by loosening the nut (23,
2. Disconnect the battery.
Figure 8-3) below the chain adjusting bolt (19) on
3. Slacken the lift chains by loosening the nut (16, the lift carriage.
Figure 8-1} below the chain adjusting bolt (14) on 4. Lift the lift chains off the Yoke sheaves (18) and lay
the lift carriage. on the mast support.
4. Lift the lift chains (13) off the ram head sheaves (6) 5. Remove snap ring (15) and slide axle (16) out of

•
and lay on the mast support. yoke sheave (14). Sheave (18), bearing (2), and
5. Remove screw (1) and lock washer (2) and lift the thrust washers {1) will fall free.
ram head (4) off the lift cylinder. 6. The yoke sheave (14) can now be removed by
6. The ram head can now be repaired or replace as removing screw (17).
required. 7. Reinstall Yoke Sheave in reverse order of removal.
7. Reinstall ram head in reverse order of removal. 8. Adjust lift chains as described in paragraph 8-4.
8. Adjust lift chains as described in paragraph 8-4.
8-4. LIFT CHAIN ADJUSTMENT
8-2.2. Telescopic Trucks
NOTE: The lift chains should be adjusted with the lift
The ram head may be replaced as an assembly com- carriage fully lowered. All slack must be re-
plete with sheaves; or any part in the assembly may be moved from chains. If there is slack in any
replaced. chain, adjust the chain. Chains should be
equally taut.
WARNING: Before attempting any service make cer-
tain power is disconnected. WARNING: Before attempting any adjustment make
certain power is disconnected.
1. Lower the lift carriage fully.
2. Disconnect the battery. 8-4.1. Telescopic and Non-Telescopic Trucks
3. Slacken the lift chains by loosening the nut (16, 1. Fully lower lift carriage.
Figure 8-2) below the chain adjusting bolt (14) on 2. Disconnect the battery.
the lift carriage.
3. Loosen jam nut (3, Figure 8-1 or 24, Figure 8-2) on
4. Lift the lift chains (29) off the ram head sheaves (22) chain adjusting bolt on the lift carriage.
and lay on the mast support. 4. Take up slack by tightening nut (16, Figure 8-1 or

•
5. Remove screw (18), lockwasher (19), from top of Figure 8-2) on the bottom of the chain adjusting
ram head (20) . bolt.

PDM0495 8-1

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 ~==:t 4
~·
~~,&·
-~~
/
-
10
1112

13 22

17 19 L:KT
CAR AGE
TO
OUTER

/[t
MAST
J---'3

18 17=:::.,....- 18
) 14_.8
---- 3 I /

/ -
/
v· 15::*
16 I
--

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/
/

.____
k2o
..
21
R1555

Figure 8-1. Standard Masts {Nontelescopic)

CAUTION: At least 3 full threads must be present 3. Loosen jam nut (21, Figure 8-3) on chain adjusting
below hex nut after completion of adjust- bolt on the back of the lift carriage.
ment. 4. Take up slack by tightening nut (23) on the bottom
of the chain adjusting bolt.
5. Secure adjustment by tightening nut (3, Rgure 8-1
or nut 24, Figure 8-2). CAUTION: At least 3 full threads must be present
6. Reconnect battery. below hex nut after completion of adjust-
7. Test chain by operating carriage. If slack is still ment.
apparent repeat above procedure.
5. Secure adjustment by tightening nut (21 ).
8-4.2. Full Free Lift Trucks 6. Reconnect battery.

~·
1. Fully lower lift carriage. 7. Test chain by operating carriage. If slack is still
2. Disconnect the battery. apparent repeat above procedure.

8-2 PDM0495

https://forklift-manuals.jimdofree.com
•
18

!I/19
( i:.
13
17 20

~ dJ~21
a~/~,
22 26

~28
23
,.. I 9
/
I /
/
/
/

10

2
7~
31
2
LIFT
TO CARRIAGE
INNER

v29
30
MAST

12~y""ll
II 14 /

24 l// ~
34 16

•
R1556

Figure 8-2. Standard Masts (Telescopic)

8-5. LIFT CHAIN REPLACEMENT 3. Remove the cotter pin (18 Figure 8-1 or 11, Figure
8-2) and clevis pin (17, Figure 8-1 or 17, Figure 8-2)
from end of chain connected to mast cross brace.
8-5.1. Telescopic and Non-Telescopic Trucks
4. Remove the cotter pin (18 Figure 8-1 or 11, Figure
1 . Place a solid block on floor underthe vertical mem- 8-2) and clevis pin (17, Figure 8-1 or 17, Figure 8-2)
bers nearest the center of the lift carriage. from end of chain connected to lift carriage.
5. Remove chain from sheave (6, Figure 8-1 or 22,
2. Lower lift carriage until it is supported by the block Figure 8-2) and lay aside for repair.
and the load chains are slack, then disconnect
battery. 6. Position new chain in place on sheave.
7. Connect end of chain to lift carriage adjusting bolt

•
WARNING: Before attempting any actual replace- (14, Figure 8-1 or Figure 8-2) with the clevis pin (17,
ment, make certain power is discon- Figure 8-1 or 12, Figure 8-2) and cotter pin (18,
nected. Figure 8-1 or 11, Figure 8-2).

PDM0495 8-3

https://forklift-manuals.jimdofree.com
 41
9----r
TO
OUTER
MAST
~24

I!~L---19
< Z2__.l' _-- 21
13~
22 TO
LIFT
CYLINDER

20~
23

R1557

Figure 8-3. Inner and Outer Masts - Full Free Lift

8. Connect end of chain to chain anchor on mast cross 3. Remove the cotter pin (22, Figure 8-3) and clevis
brace with the clevis pin (17, Rgure 8-1 or 12, pin (13) from end of chain connected to mast cross
Figure 8-2) and cotter pin (18, Rgure 8-1 or 11, brace.
Figure 8-2).
4. Remove the cotter pin (22) and clevis pin (13) from
9. Adjust chain according to paragraph 8-4. end of chain connected to lift carriage.

8-5.2. Full Free Lift Trucks 5. Remove chain from sheave (18) and lay aside for
repair.
1. Place a solid block on floor under the vertical mem-
bers nearest the center of the lift carriage. 6. Position new chain in place on sheave.

2. Lower lift carriage until it is supported by the block 7. Connect end of chain to lift carriage adjusting bolt
and the load chains are slack, then disconnect (19) with the clevis pin (13) and cotter pin (22).
battery. 8. Connect end of chain to chain anchor on lift cylinder
with the clevis pin (13) and cotter pin (22, Rgure
WARNING: Before attempting any actual replace-
8-2).
ment, make certain power is discon-

•
nected. 9. Adjust chain according to paragraph 8-4.

8-4 PDM0495

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•
8-6. LIFT CYLINDER REMOVAL 4. Remove the swivel elbow , reducer, and the flow
control valve at the bottom of the lift cylinder.
8-6.1. Non-Telescopic and Telescopic.
5. Remove the nipple, reducer and street elbow from
WARNING: Before disconnecting any hydraulic lines, the bottom of the lift cylinder.
make certain the system is not under 6. Using another lift truck or suitable jack, raise lift
pressure. Refer to paragraph 9-1. carriage far enough to remove chains from around
sheaves. Lay chains aside and lower lift carriage.
1. Raise the lift carriage to approximately three-feet or
high enough to gain access to the flow control valve 7. Remove the hex head cap screw, (6) lock washer
located at the bottom of the lift cylinder. (7) and flat washer (8) securing the top of lift cylin-
der to the inner mast.
2. Place a strong support under the forks or lift car-
riage and lower until forks or carriage are resting 8. Remove the hex head cap screw, (6) lock washer
securely on the support. (7) and flat washer (8) securing the bottom of lift
cylinder to the outer mast (33).
3. Disconnect the battery.
4. Disconnect the overflow hose from top of lift WARNING: Lift cylinder must be supported during the
cylinder. next step.
5. Remove the hose retainers from the lift cylinder. 9. Support lift cylinder and using another lift truck or
6. Remove hose assembly and the swivel elbow and suitable jack, raise inner mast (36) far enough to
the flow control valve at the bottom of the lift cylin- clear top of lift cylinder.
der. 10. Lift cylinder up and out of truck.
7. Remove the nipple, reducer and street elbow from 11. Remove the yoke sheaves as described in para-
the bottom of the lift cylinder. graph 8-3.
8. Remove the ram head as described in paragraph

•
NOTE: Disassembly procedures are covered in sec-
8-2 . tion 9.
CAUTION: Hold lift cylinder securely during the final 12. Reinstall lift cylinder in reverse order of removal.
stages of this procedure.
13. Adjust lift chains as described in paragraph 8-4.
9. Non-Telescopic: Remove lift cylinder clamp (1 0,
Rgure 8-1) by removing nuts (12) and lockwashers 8-7. INNER MAST REMOVAL.
(11 ). 1. Remove the lift carriage as described in paragraph
10. Remove screw (21, Figure 8-1 or 3, Rgure 8-2) and 8-8.
washers (11 and 20, Rgure 8-1 or 1 and 2, Rgure
WARNING: Block the drive wheel securely so it can-
8-2) from bottom of lift cylinder.
not move.
11 . Raise the lift cylinder up and out of the truck.
2. Disconnect battery.
NOTE: Disassembly of lift cylinder is covered in Sec-
tion 9. CAUTION: Before disconnecting any hydraulic lines,
make certain the system is not under
12. Reinstall lift cylinder in reverse order of removal. pressure. Refer to paragraph 9-1.
13. Adjust chain according to paragraph 8-4. 3. Disconnect the hydraulic hoses from the lift
cylinder.
8-6.2. Full Free Lift
4. Remove lift cylinder as described in paragraph 8-6.
WARNING: Before disconnecting any hydraulic lines, 5. Use a chain hoist to remove the inner mast(s) from
make certain the system is not under chassis frame.
pressure. Refer to paragraph 9-1.
CAUTION: Do not lean mast against wall or where it
1 . Fully lower the lift carriage. may accidentally fall or be hit.

• 2. Disconnect the battery.

3. Disconnect hose at the bottom of lift cylinder.

PDM0495
6. Installation of the mast is performed in the reverse
order of removal.

8-5

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 7. Lubricate the newly installed mast as described in 8-10. ADJUSTABLE STRADDLES
paragraph 8-9.

8-8. LIFT CARRIAGE AND MAST REPLACEMENT.

To change the straddle dimensions using the following
procedure.
41
1. Place a solid block on floor under the vertical mem- 1. Disconnect the battery and set brake (handle up
bers nearest the center of the lift carriage. position).
2. Lower lift carriage until it is supported by the block 2. Block the truck frame on one side so that the
and the load chains are slack, then disconnect straddle leg wheel just clears the floor.
battery.
CAUTION: Secure truck to prevent tipping.
WARNING: Before attempting any actual replace-
ment, make certain power is discon- 3. Remove the two straddle bolts on each side and
nected. slide the straddles to the dimension required (mini-
mum 38 inches, maximum 50 inches).
3. Remove cotter pin and clevis pin securing chain to 4. Lubricate the straddles with grease as shown in
lift carriage. Figure 8-6.
4. On telescopic and full free lift trucks remove stop
blocks on top of mast. CAUTION: Both straddles must be adjusted with
equal number of holes exposed on each
5. On ITA lift carriages, remove hex cap screw (3,
side.
Rgure 8-4), flat washer (19), lockwasher (2) and
retainer bar (16). 5. Retighten the straddle bolts to 200 ft lbs.
6. For ITA lift carriages perform step a. for shaft type
lift carriages perform substeps b through e. 8-11. BASE AND FRAME
a. Loosen adjusting pins (20) on forks and slide
forks from lift carriage. 8-11.1. Cabinet Door Latch
b. Remove snap ring (3, Figure 8-5). 1. Install spring latch (35, Figure 8-7) on cabinet door
(24) using two screws (33) and nuts (25).
c. Place supports under forks.
2. Install door stop bracket (19) and loosely attach
d. Slide shaft 2, out of carriage. with two nuts (17), lockwashers (16), flat washers
e. Remove forks. {20) and screws (18).
3. Position bracket (19) as far toward cabinet opening
7. Remove lift carriage from mast using a chain hoist.
as the slots will allow and tighten nuts (17) finger
8. Installation of new or modified lift carriage is per- tight.
formed in the reverse order of removal.
4. Close the cabinet door (24) until the door is flush
9. Adjust chain according to paragraph 8-4. with the frame.

8-9. MAST LUBRICATION PROCEDURE NOTE: The door pushes the bracket in to its correct
position.
Fully lower the lift carriage
1. Apply a Uthium base general purpose grease using 5. Open the door without disturbing the position of the
a lubrication gun, to the grease fittings of the follow- bracket. Tighten the nuts (17).
ing components:
8-11.2. Battery Compartment Cover Removal
a. Outer-mast rollers
Compartment doors (8) are hinged and held in place
b. Chain sheaves
with clamp-on latches (9).
c. Inner mast rollers
1. Remove truss head screw (10) and washer (11)
d Lift carriage rollers then latch (9).
2. Apply a Lithium base general purpose grease with 2. To remove door, unscrew the flat head screw {18),
a brush to the full length of masts where rollers hex nut (17) and lockwasher (16), then set door
touch. aside.

PDM0495

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• 4
SEE SECTION 12
FOR ADJUSTABLE
STRADDLE OPTIONS

12. J
II~
10 _...
13.....-- T
vI "'

R1736

• 8-11.3.

handle (30).
Figure 8-4.

Battery Connector Replacement

Lift Carriage (Shaft Type) Telescopic and Nontelescopic and FFL

1 Disengage battery connectors (23) by pulling up on

4. To replace upper battery connector or handle, re-
move screws (5) and nuts (1 ).
5. Disconnect battery cables from connector.
6. Install new connector (23) or handle as applicable.
2. Remove lower connector (23) by removing screws
Be sure to install Label (29} on replacement handle.
(2).
3. Disconnect cables from connector.

• PDM0495 8-7

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 41

' '
'
'

·:~v~"~~l
R953

Figure 8-5. ITA Lift Carriages

PDM0495

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• TYPICAL POM INSTALLATION

ADUSTABLE
STRADOLE I.Q
Mti!MUM- 38"
MAXIMUM-$>"

~CTORQU~
4j ~200 FT-LBS)
4'-.1,.
I

.I
.
t"~

•
R5392

Figure 8-6. Adjustable Straddle Frame

• PDM0495 8-9

https://forklift-manuals.jimdofree.com
 ...

•
--B

•
R5389

Figure 8-7. Base and Frame

8-10 PDM0495

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• 9-1. RELIEVING SYSTEM PRESSURE.

WARNING: Hydraulic system pressure must be re-

SECTION 9
HYDRAULIC SYSTEM SERVICING

6. Reconnect battery.
7. Operate the hydraulic controls and check for leaks.
lieved before removing hydraulic system
components. Use the following procedure 9-3. FILTER REPLACEMENT.
to relieve system pressure: WARNING: Before disconnecting any hydraulic lines,
1. Fully lower the lift carriage unless the procedure for make certain the system is not under
a component directs differently. pressure. Refer to paragraph 9-1.

2. Disconnect battery. 1. Lower the lift carriage fully.

CAUTION: Use rags and a suitable container to catch 2. Disconnect the battery.
any dripping oil when the hydraulic lines 3. Remove reservoir drain plug {22, Figure 9-3 or 21,
are disconnected. Wipe off any spilled oil Figure 9-4) and drain hydraulic oil into a suitable
immediately. container.
3. Obtain a suitable container to catch any oil that may 4. Remove short section of vinyl hose {15, Figure 9-3
escape when opening a line. or 14, Figure 9-4) that connects filter to the pump.
4. Open the low pressure line at any convenient con- 5. Unscrew filter (17, Figure 9-3 or 16, Figure 9-4)
nection near the component that is to be repaired from reservoir (2).
or replaced.
NOTE: Hold filter with another wrench so that twisting
9-2. LINE, FITTING and HOSE REPLACEMENT. force is not against hose and fittings but

•
wrench against wrench .
NOTE: Leaking hydraulic fittings can sometimes be
remedied by simply tightening the fitting. If this 6. Disconnect nipple {16, Figure 9-3 or 15, Figure 9-4)
does not remedy the leak, the fitting or line from the end of filter using a suitable open end or
must be replaced. A leak in the suction line tubing wrenches.
between the pump and the reservoir will some- 7. Reinstall new filter in truck by reversing the above
times cause hydraulic oil to foam through the procedure.
vent. 8. Clean the drain plug thoroughly.
WARNING: Before disconnecting any hydraulic lines, 9. Reinstall the drain plug.
make certain the system is not under
pressure. Refer to paragraph 9-1. NOTE: Refill only with Big Joe hydraulic oil, and only
while the lift carriage is completely lowered.
1. Remove reservoir drain plug (22, Figures 9-3 or 21, Refill until oil is to the "FULL" mark on the dip
Figure 9-4) and drain hydraulic oil into a suitable stick. Refer to Section 3 for oil capacities.
container.
10. Remove the reservoir vent cap, fill the reservoir to
2. Remove the leaking line or fitting and replace it with
the "FULL" mark on the dip stick, and replace the
a new one. Refer to Figures 9-1 , 9-2, 9-3 and 9-4.
vent cap.
3. Clean the drain plug thoroughly.
11. Reconnect battery.
4. Reinstall the drain plug.
12. Operate the hydraulic controls and check for leaks.
NOTE: Refill only with Big Joe hydraulic oil, and only 9-4. FLOW CONTROL VALVE
while the lift carriage is completely lowered.
1. Raise the forks high enough to gain access to the
Refill until oil is to the "FULL" mark on the dip
flow control valve (5, Figure 9-1 or 7, Figure 9-2).
stick. Refer to Section 3 for oil capacities.

•
2. Place a strong support under the inner mast on
5. Remove the reservoir vent cap, fill the reservoir to telescopic models or under lift carriage on non-tele-
the "FULL" mark on the dip stick, and replace the scopic models and lower forks so that inner mast
vent cap. or lift carriage rests on the support.

PDM0495 9-1

https://forklift-manuals.jimdofree.com
 41
7

,•

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R5421

9-2
Figure 9-1. Hydraulic Installation (TEL AND NON-TEL)

PDM0495
•
https://forklift-manuals.jimdofree.com
•

•
11

R5811

• PDM0495
Figure 9-2. Hydraulic Installation (FFL)

9-3

https://forklift-manuals.jimdofree.com
 EARLIER MODELS WITH NPT PORTS
41

5
28

r-
1
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/ I
/
/ I
,)
/

~·
28
21 27
2

R5436

Figure 9-3. Panel Assembly

41
9-4 PDM0495

https://forklift-manuals.jimdofree.com
• LATER MODELS WITH SAE PORTS

/
/
11 /
/

• 12

21~

R5437

• PDM0495
Figure 9-4. Panel Assembly

9-5

https://forklift-manuals.jimdofree.com
WARNING: Before disconnecting any hydraulic lines, 8. Reinstall assembly in truck and connect hydraulic
make certain the system is not under
pressure. Refer to paragraph 9-1.
Jines to pump and electrical wires to motor.
9. Clean the drain plug thoroughly.
41
3. Disconnect battery. 10. Reinstall the drain plug.
4. Disconnect hose assembly (21, Figure 9-3 or 20,
NOTE: Refill only with Big Joe hydraulic oil, and only
Figure 9-4) at fitting (4, Figure 9-1 or 9-2).
while the platform is completely lowered. Refill
5. Remove flow control valve (5, Figure 9-1 or 7, until oil is to the "FULL" mark on the dip stick.
Figure 9-2). Refer to Section 3 for oil capacities.
6. Install new flow control valve making certain direc-
tion of free flow (as marked on valve) is toward lift 11. Remove the reservoir vent cap, fill the reservoir to
cylinder. the "FULL" mark on the dip stick, and replace the
vent cap.
7. Install reducer (6, Figure 9-2).
12. Reconnect battery.
8. Install elbow (4, Figure 9-1 or 8, Figure 9-2) and
reconnect disconnected hose. 13. Operate the hydraulic controls and check for leaks.
9. Reconnect battery. 9-5.2. Pump and Motor Assembly 016936.
10. Raise forks, then remove support.
The hydraulic pump and motor assembly may be re-
11. Fully lower the lift carriage and check the hydraulic paired. Pump motor repair is covered in Section 10. If
oil level. the hydraulic pump and motor assembly is disassem-
11. Raise and lower the lift carriage and check for leaks. bled, the pump shaft seal (9, Figure 9-6) must be
replaced.
9-5. HYDRAULIC PUMP AND MOTOR ASSEMBLY
WARNING: Before disconnecting any hydraulic lines,
9·5.1. Pump and Motor Assembly 016912 and make certain the system is not under
016922. pressure. Refer to paragraph 9-1.
The hydraulic pump and motor assembly may be re-
paired. Pump motor repair is covered in Section 10. If
the hydraulic pump and motor assembly is disassem-
1. Remove reservoir drain plug (22, Figure 9-3 or 21,
Figure 9-4) and drain hydraulic oil into a suitable ~·
container.
bled, the gasket (2, Figure 9-5) must be replaced.
2. Disconnect hydraulic Jines from pump.
WARNING: Before disconnecting any hydraulic lines,
3. Disconnect electrical wires from motor.
make certain the system is not under
pressure. Refer to paragraph 9-1. 4. Remove the two screws (25, Figure 9-3 or 23,
Figure 9-4), attaching pump and motor assembly to
1. Remove reservoir drain plug (22, Figure 9-3 or 21, panel and remove pump and motor assembly.
Figure 9-4) and drain hydraulic oil into a suitable
5. Remove the pump bolts (13, Figure 9-6) to disas-
container.
semble the pump from the pump adapter (6).
2. Disconnect hydraulic lines from pump.
6. Remove the coupling (8) and shaft seal (9).
3. Disconnect electrical wires from motor.
7. If the pump is defective, install a new pump. If motor
4. Remove the two screws (25, Figure 9-3 or 23, is defective, a new motor may be installed, or motor
Figure 9-4), attaching pump and motor assembly to may be rebuilt. Proceed with step 8 to remove the
panel and remove pump and motor assembly. motor adapter and pump adapter.
5. Remove the four screws (5, Figure 9-5) and lock 8. Remove four screws (7) and take off pump adapter
washers (4) to disassemble the pump from the (6) and motor adapter (5). Motor can now be re-
motor. Discard gasket (2); save drive connector (3) placed or serviced (see section 1 0).
for reuse.
9. Reassemble using a new shaft seal (9).
6. If the pump is defective, install a new pump. If motor
10. Reinstall assembly in truck and connect hydraulic
is defective, a new motor may be installed, or motor

•
lines to pump and electrical wires to motor.
may be rebuilt (see section 10).
11. Clean the drain plug thoroughly.
7. Reassemble using a new gasket (2) and reuse
drive connector (3). 12. Reinstall the drain plug.

9-6 PDM0495

https://forklift-manuals.jimdofree.com
• USED ON TRUCKS PRIOR TO
SERIAL NUMBER 341476

/
/
/
/
/
/

R1666

• PDM0495
Figure 9-5. Hydraulic Pump 016912 and 016922

9-7

https://forklift-manuals.jimdofree.com
 USED ON TRUCKS
SERIAL NUMBER
341476 AND HIGHER
41

R5264

9-8
Figure 9-6. Hydraulic Pump and Motor Assembly 016936

PDM0495
•
https://forklift-manuals.jimdofree.com
• NOTE: Refill only with Big Joe hydraulic oil, and only
while the platform is completely lowered. Refill
until oil is to the "FULL" mark on the dip stick.
Refer to Section 3 for oil capacities.

13. Remove the reservoir vent cap, fill the reservoir to

the "FULL" mark on the dip stick, and replace the
NOTE: Refill only with Big Joe hydraulic oil, and only
while the platform is completely lowered. Refill
until oil is to the "FULL" mark on the dip stick.
Refer to Section 3 for oil capacities.

17. Remove the reservoir vent cap, fill the reservoir to

the "FULL" mark on the dip stick, and replace the
vent cap. vent cap.
14. Reconnect battery. 18. Reconnect battery.
15. Operate the hydraulic controls and check for leaks. 19. Operate the hydraulic controls and check for leaks.

9-6. CONTROL VALVE SERVICE 9-6.2 Disassembly of Lift Control Valve

Repair parts for the control valve are illustrated in Figure To disassemble the lift control valve proceed as follows:
9-7.
1. Loosen the lower nut (9, Figure 9-7} to release lift
control lever (7) and valve clamp (1 0), from release
9-6.1 Control Valve Replacement
cam shaft (3}.
WARNING: Before disconnecting any hydraulic lines, 2. Remove lever and clamp from the release cam (3)
make certain the system is not under and remove the handle return spring (11}.
pressure. Refer to paragraph 9-1.
3. If it is necessary to remove the motor contact switch
1. Lower the forks as far as possible. assembly (12}, remove the nut (16).
2. Check that the battery charger is turned off and that 4. Remove switch bracket (4}
the power cord to the charger is disconnected. 5. Remove reducer (20) to free compression spring
3. Disconnect the battery. (15}, check ball (14}, and valve pin (13) .

• 4. Remove the knob from the lift control and the

breather cap from the hydraulic reservoir.
5. Remove the hydraulic compartment cover.
6. Disconnect the hydraulic line from the swivel con-
nectar at the lift control valve.
6. The release cam (3) and 0-ring (2) can now be
pulled from the valve body (1 ).
7. Assemble and install the lift control valve by revers-
ing the preceding procedures.

9-6.3 Control Valve Adjustment

7. Disconnect wires connected to the hydraulic panel
assembly. The lift control valve is properly adjusted, inspected, and
8. Remove the hydraulic panel. checked thoroughly before leaving the factory. The
valve should rarely need readjusting, but if adjustment
9. Remove reservoir drain plug (22, Figure 9-3 or 21,
is necessary, the following procedure should be used to
Figure 9-4} and drain hydraulic oil into a suitable
set the valve and the hydraulic pump switch.
container.
1. With the ball seat assembly in place and the valve
10. Label and disconnect the electrical wires from the
switch (12, Figure 9-7) at the bottom of the control installed in the hydraulic system raise the life car-
valve. riage part way with a moderate load on the forks to
build up pressure in the hydraulic system.
11. Remove the control valve by removing the four
screws (17) and washers (18}. 2. Loosen the upper nut (9, Figure 9-7} on the lift
control lever (7} being careful that the clamp (10)
12. Install new or repaired control valve and secure with
does not come off the cam (3) and that the handle
the four screws (17} and washers (18).
return spring (11) remains secure at the roll pins (8}
13. Connect the wires and hoses to the control valve. to keep the lever centered and in a neutral position.
14. Reinstall hydraulic panel and compartment cover.
3. Note the point where the handle knob (6) and lever
15. Reinstall the drain plug. (7} come together as a reference point for the next
16. Reinstall the knob on the control lever. few steps.

• PDM0495 9-9

https://forklift-manuals.jimdofree.com
 41

u
/

•
I
I
I

~13
I
10

o----14 9
I
I
II

6--1s
~20

R461

9-10
Figure 9-7. Hydraulic Control Valve Assembly

PDM0495
•
https://forklift-manuals.jimdofree.com
•
4. Using the reference point noted in step 3, push the 3. Remove lift cylinder tube assembly from vise .
handle forward 3/4 inch from neutral position. With
a screwdriver in slot of release cam (3), rotate 1/8 CAUTION: Use proper pipe clamp-type vise with non-
inch clockwise. This is to make sure that check ball marring jaws to prevent damaging the
(14) is seated in the valve seat. finish on the ram.

5. With a screwdriver, tum the release cam (3) coun- 4. Secure cylinder ram rod (5) in vise.
terclockwise until a definite resistance is felt. (Re- 5. Remove nut (11) and pull off bottom washer (10), flat
sistance is felt as the pin resting on the ball pushes washer (13), packing assembly (9), piston (8), and
against the hydraulic pressure in the system). At bottom 0-ring (7).
this point, the release cam action has moved the
valve pin (13) down against the check ball (14). NOTE: Before reassembling the hydraulic lift cylinder, it
Rotation of the release cam beyond this point is recommended that the wiper ring (2), 0-rings
pushes the ball away from the valve seat and opens (4, 7) and packing assembly (9) be replaced.
the system allowing the lift carriage to descend.
6. Reassemble the cylinder in reverse order of disas-
6. When resistance is felt and, with the handle pushed sembly.
forward 3/4 inch, tighten upper nut (9) down against
the valve clamp (10). The valve should now be in 9-7.2. Full Free Lift
proper adjustment. Test by pushing the handle
NOTE: Removal procedures are covered in Section 8.
forward 1 inch and the lift carriage should start to
descend slowly. Refer to Figure 9-9 and proceed as follows.
9-6.4 Hydraulic Pump Motor Switch Adjustment CAUTION: Use proper clamp-type vise. The lift cylinder
When the release cam (3, Figure 9-7) is properly set, it will be distorted if the vise is tightened too
may be necessary to readjust the hydraulic pump motor much.

•
switch (12). A clearance of approximately 0.010 inch
1. Secure lift cylinderweldment (1) in vise and remove
should be maintained between the switch plunger and
the snap ring retainer (3) and square head pipe plug
the valve clamp (1 0) for precise control of the lift car-
(2).
riage.
1. To adjust the switch for proper clearance, loosen 2. Pull outward on the cylinder base (9) until wear ring
the two nuts (16) supplied with the switch (12). (14) contacts the cylinder base. Continued pulling
will bring the cylinder head (4) out of the tube.
2. Raise or lower the position of the switch turning the
upper nut. 3. Use a strap wrench to hold the cylinder rod (13) and
3. When there is a clearance of 0.010 inch between unscrew cylinder base (9) from cylinder rod. Re-
the switch plunger and the valve clamp, tighten the move cylinder head (4) from cylinder rod ..
lower nut on the switch.
CAUTION: As cylinder rod (13) is pulled out of cylinder
9-7. LIFT CYLINDER REPAIR tube, catch the two halves of wear ring (14)
which will be freed and may fall and be
9-7.1. Non-Telescopic and Telescopic
damaged.
NOTE: Removal procedures are covered in Section 8.
4 The cylinder rod (13) may now be pulled out of the
CAUTION: Use proper pipe clamp-type vise. The cyl- tube. Support it carefully and catch the two halves
inder will be distorted if the vise is tight- of the wear ring (14) as they are free. Continue to
ened too much. pull on the cylinder rod until the piston (12) is out of
the tube.
1. Secure lift cylinder tube assembly in vise and re-
move gland nut (3, Figure 9-8), then wiper ring (2), 5 If piston is worn or damaged hold the cylinder rod
and top 0-ring (4). (13) with a strap wrench and take off Flexloc lock
2. Pull out cylinder ram rod (5) . nut (11). Pull piston free of the rod.

• PDM0495 9-11

https://forklift-manuals.jimdofree.com
 41

3
6

:--4
4

9~
13--®
10~
•
II~
IL_ _ _ _ _ j 12-------l

L_____J

RB10

~·
Figure 9-8. Lift Cylinder - Non-Telescopic and Telescopic Trucks

9-12 PDM0495

https://forklift-manuals.jimdofree.com
•
PISTON
ROO

TOOL

18
I 900931

I
I
I
I
I CYUNOER

• I
I
I
I
I
I
23 I
/

R1583

• PDM0495
Figure 9-9. Lift Cylinder- Full Free Lift

9-13

https://forklift-manuals.jimdofree.com
 6. Examine bore of center cylinder tube of the cylinder c. A little more pulling will release the halves of the
assembly (1 ), and surfaces of the cylinder rod (13),
piston (12), and wear ring halves (14). Replace all
wear ring.
d. Catch these pieces for reuse if in good condi-
41
unsatisfactory parts and proceed with the following tions.
steps:
e. Carefully support cylinder rod (23) and pull it
a. Remove hydraulic cylinder wiper ring (7) and outward to free it and piston (20) from the tube.
"U"-cup rod seal (8) from inside of cylinder head If the piston is worn or damaged, or to replace
(4), and "0" ring (5) and back-up ring (6) from ·o·ring (21 ), hold the rod with a strap wrench
outside of cylinder head. and remove Flexloc lock nut (11) and pull piston
free of rod.
b. Clean and dry all parts.
f. Examine bore of cylinder tube being repaired,
c. Discard all used "0" rings and seals and replace
surface of cylinder rod (23) and wear ring halves
them with new ones during reassembly.
(22) for scoring, scratching, or other damage.
d. Coat all new "0" rings and seals with hydraulic
g. Replace all unsatisfactory parts and proceed
fluid during reassembly.
with the following steps:
7. Assemble FFL center cylinder by reversing the (1) Remove and discard "0" ring (21) and ·u·
disassembly procedure. For ease of assembly cup seal (19).
when assembling threaded parts, apply a coating
(2) Clean all parts and replace all "0" rings
of white lead replacement to the threads--except for
and seals during reassembly.
the threads of the cylinder base (9) which are to be
coated with Loctite 222 adhesive (24). CAUTION: Reassembly of the lift cylinder requires the
use of special tool, part number 900931, to
8. If either or both of the outer cylinders of FFL cylinder
prevent damage to cylinder packing.
assembly must be repaired, proceed as follows:

~·
(3) Insert special tool part number 900931, into
CAUTION: As cylinder rod of either outer cylinder is the end of the cylinder, as shown in Figure
pulled out of cylinder tube, the two halves of 9-9 (inset).
wear ring (22) may fall free and be damaged
hitting the floor. Be sure to catch these (4) Coat rings and seals with hydraulic fluid
pieces. during replacement.
(5) Assembly FFL outer cylinder(s) by revers-
a. Remove snap ring retainer (15). ing the disassembly procedure. For ease
b. Pull outward on the cylinder rod (23) until wear of assembly, when assembling threaded
ring (22) pushes cylinder head (16) out of cylin- parts, apply a coating of white lead replace-
der tube. ment to the threads.

9-14 PDM0495
•
https://forklift-manuals.jimdofree.com
•
SECTION 10
ELECTRICAL COMPONENTS
10-1. ELECTRICAL CONTROL PANELS. 10-2.2. 2nd Speed, 3rd Speed, Dynamic Brake Sin-
gle Pole Contactor Reassembly. (Refer to
1. SEE SUPPLEMENT 228 FOR TRANSISTOR Figure 10-1)
TRUCKS SERIAL NUMBER
338388 AND HIGHER. 1. Place 1-1/4 inch long hex head bolt through bottom
2 .. SEE SUPPLEMENT 187 FOR TRANSISTOR of front molding (4) and slide molding onto frame (2).
TRUCKS SERIAL NUMBER 2. Attach coil (11) to frame (2) with flat washer and 5/8
333620 TO 338388. inch long hex head bolt. Be sure braid assembly (3)
has been attached to frame (2) with 3/4 inch bolt,
The 12-volt panel part numbers 504659 is shown in
Figure 12-34. Rgure 12-34 identifies parts associated flat washer, lock washer and nut. Use 10mm
with the complete electrical control panel assembly. wrench on nut.
3. Attach frame (2) to base molding {1) by engaging
10-2. Contactor Servicing. slots at bottom of frame (2) behind flanges near
NOTE: One contactor tip kit part number 900531..()1 lower edge of base molding (1 ).
contains the number of contacts required to serv- 4. Snap slots oftop of front molding (4) into flanges of
ice all contactors on a truck. Contactor tip kit part base (1 ). Coil assembly should now securely attach
number 900531-09 contains contacts for the for- to base (1).
ward-reverse contactor. Contactor tip kit part
number 900531-08 contains contacts for the 2nd 5. Install spacer {13) in front molding (4) and install
and 3rd speed and dynamic brake contac:tors. front contact (12) secure with washer, lock washer
and hex nut. Use 10 mm wrench on nut.
10-2.1. 2nd Speed, 3rd Speed, Dynamic Brake Sin-
gle Pole Contactor Disassembly. (Refer to 6. Place contactor on work surface with base molding

•
Figure 10-1) down. Place spring (6) on center of pole piece (1 0).
7. Position armature plate (9) against frame (2).
NOTE: Order contactor tip kit part number 900531-
08. One kit repairs one 2nd or 3rd speed 8. Place moving contact assembly (8) on armature
contactor or the dynamic brake contactor. Kit plate then attach braid assembly (3) to contact stud.
includes items (3, 5, 8 and 12). 9. Place retainer (5) over contact stud and slip the two
1. Remove spring stud (7) and spring (6). tabs on retainer (5) into the two slots in armature
2. Remove nut holding armature plate retainer (5) and plate (9). Secure with hex nut.
remove retainer by squeezing in on tabs and lifting up. 10. Secure moving contact (8) to armature (9) with
3. Slide braid assembly (3) off contact (8) and remove spring (6) and spring stud (7).
contact (8) and armature plate (9) and spring (6). 10-2.3. Forward-Reverse Double Pole Contactor
4. Use a 10 mm wrench to remove nut and flat washer Disassembly. (Refer to Figure 10-2)
holding front contact (12) and remove contact. NOTE: Order contactor tip kit part number 900531-09.
NOTE: If only contacts are to be replaced, no further One kit repairs one contactor. Kit includes
items (3, 5, 8, 12 and 16).
disassembly is required. Proceed to step 5 to
replace coil. 1. Remove spring (7) and spring {6).

5. Remove spacer (13). 2. Remove nut bolt and washer securing bus bar (14),
(if used) to back contact (16).
6. Squeeze sides of front molding (4) and pull forward
to disengage from base molding (1 ). Remove base 3. Slide back contact (16) up as far as possible then
molding and remove front molding from frame (2). squeeze sides of rear molding (17) together and lift
off frame (2). Separate two sides of rear molding
7. Coil can now be removed from frame (2) by remov- and remove back contact (16).
ing 3/4 inch long hex head screw and flat washer.
4. Remove nut holding armature plate retainer (5) and

•
remove retainer by squeezing in on tabs and lifting up.

PDM0495 10-1

https://forklift-manuals.jimdofree.com
 CONTACTOR TIP KIT
901531.08 CONTAINS
ITEM QTY
41
3 1
4 1
8 1
12 1

R1865

Figure 10-1. Single Pole Contactor, 2nd Speed, 3rd Speed Dynamic Brake
•
5. Slide braid assembly (3) off contact (8) and remove 10-2.4. Forward-Reverse Double Pole Contactor
contact (8) and armature plate (9) and spring (6). Reassembly. (Refer to Figure 10-2)
6. Use a 10 mm wrench to remove nut holding front 1. Place 1-1/4 inch long hex head bolt through bottom
contact (12) and remove contact. of front molding (4) and slide molding onto frame (2).
NOTE: If only contacts are to be replaced, no further 2. Attach coil (11) to frame (2) with flat washer and 5/8
disassembly is required. Proceed to step 7 to inch long hex head bolt. Be sure braid assembly (3)
replace coil. has been attached to frame (2) with 3/4 inch bolt,
7. Remove spacer (13). lock washer, flat washer and nut. Use 10 mm
wrench on nut.
8. Squeeze sides of front molding (4) and pull forward
to disengage from base molding (1 ). Remove base 3. Attach frame (2) to base molding (1) by engaging
molding and remove front molding from frame (2). slots of bottom of frame (2) behind flanges near
lower edge of base molding (1).
9. Coil can now be removed from frame (2) by remov-
ing 3/4 inch long hex head screw and flat washer. 4. Snap slots at top of front molding (4) into flanges of
base (1). Coil assembly should now be securely
attached to base (1 ).

10-2 PDM0495

https://forklift-manuals.jimdofree.com
• 3
5
CONTACTOR
TIP KIT 900531-09

ITEM
CONTAINS
QTY
1
1
8 1
5/SIN LG
12 2 13
16 2

• R1866

Figure 10-2. Double Pole Contactor, Forward, Reverse

5. Install spacer (13} in front molding (4} and install 10. Place two parts of back molding (17) together and
front contact (12} secure with washer, lock washer slide contact (16} into slot in molding.
and hex nut. Use a 10 mm wrench on nut.
11. Squeeze back molding together and place grooves
6. Place contactor on work surface with base molding in back molding on frame (2). Push molding all the
down. Place spring (6) on center of pole piece (1 0}. way down.
7. Position armature plate (9} against frame (2). 12. Release back molding and press back contact (16)
down into position. Armature will need to be
8. Place moving contact assembly (8} on armature
pressed down to position back contact.
plate then attach braid assembly (3) to contact stud.
13. Reattach bus bar (14} (if used} to back contact (16}
9. Place retainer (5) on contact stud and slip the two
using hex nut and washers.
tabs on retainer (5) into the two slots in armature
plate (9}. Secure with hex nut. 14. Secure moving contact (8) to armature (9} with
spring (6) and spring stud (7} .

• PDM0495 10-3

https://forklift-manuals.jimdofree.com
10-3. PUMP MOTORS. 3. Disconnect the battery cables from the battery ter-
Three different pump motor assemblies have been used
on the PDM Truck. Refer to the following chart to deter-
mine the proper pump motor.
minals.
4. Lift the battery out of the battery compartment.
5. Lower the new battery in the battery compartment.
41
VOLTS PUMP MOTOR SERIAL NO. 6. Reconnect the battery cables to the battery termi-
nals.
DC PART NO. EFFECTIVITY
5. Reconnect the battery quick disconnect (28).
12 901528 341476 AND HIGHER
12 905035 333620 THRU 333652 AND 10-6. HIGH SPEED LIMIT SWITCH.
333890 THRU 341475
1. Remove the two screws securing switch to frame.
12 904140 333653 THRU 333889
2. Remove high speed limit switch (Figure 10-3) and
then disconnect wiring from the switch.
3. Connect the wiring to the new switch and install the
NOTE: Removal procedures are covered in Section 8.
switch.
Refer to applicable Figure 12-29, 12-31, and 12-32 for
NOTE: Switch must be positioned so that switch is
motor disassembly.
operated when lift carriage is down.
10-4. DRIVE MOTORS. 4. Position new switch in place on frame, and secure
with two washers, two lock washers, and two
NOTE: Removal procedures are covered in Section 6.
screws.
Refer to Figure 12-33 for motor disassembly.
10-7. BATTERY CHARGERS.
10-5. BATTERIES. The Smart Charger Part number 004975-01 is directly
1. Turn key to off, and remove from key switch. interchangeable and replaces the manual 30-Amp
Timer Charger Part Number 004950. These charges

~·
NOTE: Batteries are heavy. Use care when lifting out operate on 120 V 60 Hz input. The timer Charger Part
of battery compartment. number 004951, operates on 230 V 50 Hz input. Sche-
matic diagrams of the charges are shown in Figures
2. Disconnect the battery quick disconnect (10, Figure
12-10). 1Q-4 and 10-5. Parts identification information is shown
in Figure 12-37 and 12-38.

10-4 PDM0495

https://forklift-manuals.jimdofree.com
•
HIGH SPEED
' - - - + - - L I M I T SWITCH
STANDARD WN 020703
COLD CCIIIOtTIOMNG IVN020689
BATTERY
COMPARTMENT

OUTER
MAST

R5435

Figure 10-3. High Speed Limit Switch

• CONTROL
TRANSFORMER
TX2
11
7
lll~-----:.~-1 VFC2200
13

IBLK ~~~~~r-~------~nr----~~-+--------~---+~
TRIAC DC
__j
I GREEN~
AC -:;:- AMMETER

LWHC'o--------1'-------' SCHEMATIC DIAGRAM

•
R5270

Figure 10-4. "SMART" Battery Charger 00497!H>1 Schematic Diagram

PDM0495 10-5

https://forklift-manuals.jimdofree.com
 41

P/0 61
TIMER Tl CRI
CONTACT
P2 A

WHITE
+
CR2
120 VAC D
INPUT

Cl

":'
WHITE
PI OCI ~~
CIRCUIT
BREAKER
A -

THERMAL
OVERLOAO

R328

Figure 10-5. 30-Amp Timer Battery Charger Schematic

~·
10-6 PDM0495

https://forklift-manuals.jimdofree.com
•
SECTION 11
OPTIONAL EQUIPMENT

11-1. KEYSWITCH 11-3. BATTERY CAPACITY INDICATOR.

Those trucks which have a keyswitch installed will have Refer to Rgure 12-40 and 12-41 for the battery capacity
the wiring modified. The modification and the schematic indicator replacement parts.
diagram are shown in Figure 12-42.
11-4. REMOTE CONTROL.
11-2. HOUR METER
Refer to Rgure 12-25 and 12-26 for removal and parts
The hour meter is attached to the motor circuits to identification of the remote control option.
indicate actual usage of the drive and lift function. Refer
to Figure 12-39 for replacement parts and to the sche-
matic diagram, Figure 4-1 for wiring information .

• PDM0495 11-1

https://forklift-manuals.jimdofree.com
 NOTES
41

11-2 PDM0495
•
https://forklift-manuals.jimdofree.com
•
SECTION 12
ILLUSTRATED PARTS BREAKDOWN

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

• PDM0495 12-1

https://forklift-manuals.jimdofree.com
 1. SEE SUPPLEMENT 220 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL
41
NUMBER 334631 AND HIGHER
2. SEE SUPPLEMENT 207 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL
NUMBER 333620 TO 334630

SEE FIGURE 12-2

FOR SWITCHES

SEE FIGURE 12-3

FOR COLD CONDITIONING

R3837

Figure 12-1 Control Head Assembly Part Number 505050

12-2 PDM0495

https://forklift-manuals.jimdofree.com
https://forklift-manuals.jimdofree.com
 1. SEE SUPPLEMENT 220 FOR TRANSISTOR 2. SEE SUPPLEMENT 207 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL SPEED CONTROL TRUCKS SERIAL
NUMBER 334631 AND HIGHER NUMBER 333620 TO 334630

PDM WITH LIFT ONLY PDMWITH HORN AND BRAKE

505050-02 (OPTION) 5050~1, 02 & 03 (STANDARD)

16

11-----Q

3~~
R5215

PDM WITH LIFT AND LOWER

505050-03 (OPTION)

R5217

PDM 505050-01
(STANDARD)
~·

R5216 R5218

Figure 12-2. Control Head Pushbutton Switches

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 005643 CONTACT PIN 2MAX. 11 056641-03 LIFT DECAL 1
2 005649 CONNECTOR 1 12 056641-04 LOWER DECAL 1
3 020697 PUSHBUTTON SWITCH - BLACK 2MAX 13 067415 PAN HD. SCREW 6-32 X 1/4 AR
4 020698 PUSHBUTTON SWITCH - RED 1 14 067416 PAN HD. SCREW, 6-32 X 1!.2 4
5 021208 TERMINAL 4MAX. 15 402830 TOP COVER 1
6 023014 WIRE AR 16 402831 TOP COVER 1
7 023169 WIRE HARNESS ASSEMBLY 1 17 402832 TOP COVER 1
9 053215-03 HOLE PLUG 1 18 402842 SWITCH PLATE 1
10 056619-01 HORN DECAL 1 19 056641-02 BRAKE DECAL 1

AR -AS REQUIRED 41
12-4 PDM0495

https://forklift-manuals.jimdofree.com
•
1

•
R3966

Figure 12-3 Cold Conditioning, Control Head Assembly Part Number 505050

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 018909 RESISTORS 2 9 072400-Q1 HEX HD. SLOTTED SCREW, 2
2 068186 SCREW 2 6-32 X 1/2
3 023014 WIRE AR 10 059632 NUT, HEX, 5-40 2
4 400544 BRACKET, RESISTOR 1 11 400044 BRACKET THERMAL CUTOUT 1
5 018214 INSULATOR, SWITCH 1 12 020736 THERMAL CUTOUT SWITCH 1
6 402829 BRACKET 1 13 005643 CONTACT PIN 2
7 077007 WASHER, FLAT 2 14 403372 INSULATION BUSHING 2
8 077204 SPLIT LOCK WASHER #6 2

• PDM0495 12-5

https://forklift-manuals.jimdofree.com
 SEE SUPPLEMENT 228 FOR
TRANSISTOR SPEED
CONTROL TRUCKS
SEE SUPPLEMENT 318
FOR CONTROL ARM
ASSEMBLY
HANDLE RETURN SPRING
KIT 901325 CONTAINS
ITEM QTY
41
1 1
2 1
6 1

o--21
7 1
8 2
9 2
13 1
14 1

14 1
1/4 INC0 / ) - : -
ROLL P I ¥ -

13
3/BINCH
ROLL PIN
~·
18
RS385
''
25
'
16)...--1 l
USED ON TRUCKS
SERIAL NUMBER 15 ?4
)12
333620 TO 346721,
346723 TO 346750,
22"1 346752 TO 346926,
346928 TO 346934
21~,
: Q AND 346936
Q

RS384

Figure 12-4 Steering Arm, Pivot Cap and Electrical Control Cable
fl
12-6 PDM0495

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•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 501371* SPRING TUBE ASSY 1 16 401127 SPACER 1
2 075060* STEERING ARM RETURN 1 17 065481 SOCKET HEAD SCREW, 4
SPRING 1/4-20 X 1
3 402363*** PIVOT CAP 1 18 052925 FLANGED BEARING 1
3 800206** PIVOT CAP 1 19 501673 BRAKE ROD
4 052876 BUMPER 1 20 060417 COTIER PIN, 3/32 X 3/4 1
5 071376 PAN HEAD SCREW, 10-32 X 1/2 3 21 402459*** PIVOT CAP COVER 1
6 285302* SPRING PIN, 1/4 1 21 191045** PIVOT CAP COVER 1
7 285303* SPRING PIN, 318 1 22 065603** SOCKET HEAD SCREW, 2
8 077210* LOCK WASHER, 5/16 2 3/8-16 X 3/4
9 059426* HEX NUT, 5/16-18 2 23 503975 CABLE CLAMP AND NUT ASSY 2
10 800204 TUBE CLAMP 1 24 069478 PHILLIPS FLAT HD. SCREW, 2
11 052922 FLANGED BEARING 1 1/4-20 X 3/4
12 800275 STEERING ARM 1 25 023083 CONTROL CABLE 1
13 061050* ROLL PIN, 318 X 1-1/4 1 26 061716*** SNAP RING 2
14 061006* ROLL PIN, 1/4 X 1-1/4 1 27 402452*** PIN 1
15 065569 SOCKET HEAD SCREW, 1
7/16-14 X 2-1/4

* HANDLE RETURN SPRING KIT 901325

** USED ON TRUCKS SERIAL NUMBER
333620 TO 346721, 346723 TO 346750,
346752 TO 346926, 346928 TO 346934,
AND 346936
*** USED ON TRUCKS SERIAL NUMBER

•
346722,346751,346927,346935,
346937 AND HIGHER

• PDM0495 12-7

https://forklift-manuals.jimdofree.com
 41
.,.
I

4 ~o:

5~:
~ I,."'

613--s 10 ---
11--t.af(
12y~
I

!~

R5387

Figure 12-5. Pivot Tube Assembly

INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 - TRANSMISSION (FIG. 12-8) REF 7 505682-01** PIVOT TUBE WELDMENT 1
2 065538 SCREW, 5/16-18 X 5/8 1 (SEE NOTE2)
3 053107 BUSHING, PIVOT 1 8 064709 SCREW, HEX HEAD, 4
4 061000 ROLL PIN, 1/4 X 3/4 1 1/2-13X 1-1/2
5 053108 BUSHING PIVOT 1 9 077412 LOCK WASHER EXTERNAL 4
6 051146 BEARING, THRUST 1 10 060417 COTIERPIN 1
7 500351* PIVOT TUBE WELDMENT 1 11 283902 SPRING SUPPORT 1
(SEE NOTE 1) 12 800005 SPRING SUPPORT PIN 1
13 075022 TRACTION SPRING 1

NOTE 1: ORDER PIVOT TUBE KIT PART NUMBER * USED ON TRUCKS SERIAL NUMBER
903277. 333620 TO 346721, 346723 TO 346750,
346752 TO 346926, 346928 TO 346934,
NOTE 2: TOOL KIT PART NUMBER 907151 REQUIRED
AND 346936
FOR REMOVAL AND INSTALLATION OF
PIVOT TUBE WELDMENT PART NUMBER ** USED ON TRUCKS SERIAL NUMBER
505682-01. 346722,346751,346927,346935,
346937 AND HIGHER

12-8 PDM0495

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•
NOTES

• PDM0495 12-9

https://forklift-manuals.jimdofree.com
 USED ON TRUCKS SERIAL
NUMBER 333761 AND HIGHER

•
2
4----11
'3 __;~IIL"-7--2
HORN REF ,42
~~25 41
.-~24 /
"""
/
/
/
/

-~2

~·

R3297

Figure 12-6. Brake and Linkage

12-10 PDM0495
•
https://forklift-manuals.jimdofree.com
•
INDEX PART NO . INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 053109 LOCK BUSHING 6 24 077211 LOCK WASHER, 3/8 2
2 060417 COTTER PIN, 3/32 X 3/4 10 25 064605 HEX HEAD CAP SCREW, 1
3 053106 FLANGED BUSHING 2 3/8-16 X 1, HEAT TREATED
4 111104 UPPER PIVOT PLATE 1 26 800119 CLEVIS 1
5 111105 LOWER PIVOT PLATE 1 27 052821 DISC BRAKE CALIPER ASSY 1
6 060320 CLEVIS PIN 2 28 059421 HEX NUT, 1/4-20 2
7 060316 CLEVIS PIN, 1/4 X 1 1 29 077209 LOCK WASHER 2
8 500202 BRAKE ROD 1 30 901189 BOLT 2
9 505206 LEVER ASSEMBLY 1 31 901190 SPACER 2
10 505199 BRACKET 1 32 901191 SPRING 2
11 060310 CLEVIS PIN 1 33 901188 BRAKE PAD 1
12 258127 PIN 1 34 901198 C-RING 1
13 800284 CLEVIS 1 35 901197 WASHER 1
14 059427 NUT, 5/16-24 2 36 901196 SPRING 1
15 258126 ROD, THREADED 1 37 901192 BRAKE PAD WITH PIN 1
16 500201 TUBE BRAKE ROD 1 38 901195 BRACKET 1
17 505208 MOUNTING PLATE 1 39 901194 LEVER 1
WELDMENT- BRAKE 40 901193 WASHER 1
18 057903 KEY, 1/4 X 1/4 X 1 1 41 068336 ROUND HEAD SCREW, 2
19 505207 DISC ASSEMBLY 1 6-32S 1-1/2
20 077215 LOCK WASHER, 5/8 6 42 - SWITCH-DEADMAN REF
21 059645 LOCKNUT, 5/8-18 1 (FIG. 12-10)
22 077210 LOCK WASHER, 5/16 4 REF 009600 HORN12V 1
23 063557 SCREW, CAP, HEX HD, 4
5/16-18 X 1-1/4

• PDM0495 12-11

https://forklift-manuals.jimdofree.com
 41
BRAKE PAD KIT

::o~~:g~~i~~
ITEM 1
22 1
23 2
24 2
25 2
/'
,--- -.... ,, I
26 2
37 .,
I
'' ......... __-~I
-,.,,/
1· 5
1I ' - - - -
2 ' .... _

~fr I

35

I ~·
BRAKE 3
L£VER
ACCESS
3 - ........... HOLE
5 ,. -, . . .
fi!.J....,/ ........
'-,) /-::...-:......,
I / / I
I I / ;;.... I
I ',, ,,
I//~/
I
\
', I j 1 { '..,_f/.
.... , __ I I ' ..... _ I ............
~ I ;
'\._,., ....

27 24

31

Figure 12-7. Brake and Linkage

12-12 PDM0495
•
https://forklift-manuals.jimdofree.com
•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO . PART NAME REQD.

1 056200 CLEVIS 1 21 800119 CLEVIS 1

2 060300 CLEVIS PIN 3 - 052857 CLAMPASSY 1
3 060417 COTTER PIN. 3/32 X 3/4 10 22 052863* CLAMP, BRAKE 1
4 111104 UPPER PIVOT PLATE 1 23 052860* LEVER, BRAKE 1
5 053109 LOCK BUSHING 6 24 052859* PAD, BRAKE 2
6 053106 FLANGED BUSHING 2 25 052861* HEX HEAD SOLT 2
7 500201 TUBE BRAKE FOR 1 26 052862* NUT, BRAKE 2
8 111105 LOWER PIVOT PLATE 1 27 111706 PLATE, MOUNTING 1
9 500202 BRAKE ROD 1 28 077210 LOCK WASHER, 5/16 6
10 500424 LOWER LEVER ASSY 1 29 063552 HEX HEAD CAP SCREW. 5/16 6
- 053109 LOCK BUSHING REF 30 057900 KEY. 1/4 X 1/4 X 1 1
11 258107 PIVOT PIN 1 31 503083 DISCASSY 1
12 500197 MOUNTING BRACKET ASSY 1 32 077215 LOCK WASHER, 5/8 1
13 - HORN 12V (FIG 12-10) REF 33 059645 LOCKNUT, 5/8-18 1
14 077211 LOCK WASHER 3/8 2 34 - SWITCH-DEADMAN REF
15 064605 HEX HEAD CAP SCREW, 2 (FIG. 12-10)
3/8-16 X 1, HEAT TREATED 35 068336 ROUND HEAD SCREW, 2
16 258121 ROD 1 6-32 X 1-112
17 059427 HEX NUT 3 36 059412 HEX NUT 2
18 060300 CLEVIS PIN 1 37 075070* SPRING 2
19 060417 COTTER PIN, 3/32 X 3/4 2
20 502814 WELDMENTTUBE 1
* BRAKE PAD KIT PART NUMBER 800182

• PDM0495 12-13

https://forklift-manuals.jimdofree.com
----------
 41

~·
----
Figure 12-8. Transmissi~on~A~s~s;;bW"------
... embly

12-14 PDM0495

https://forklift-manuals.jimdofree.com
•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 501720 TRANSMISSION ASSY 1 25 064615 HEX HEAD CAP SCREW, 2
1 050700 AXLE SHAFT 1 3/8-16 X 2-1/4
2 073504 OIL SEAL 1 26 060428 COTIER PIN 1
3 051112 ROLLER BEARING CONE 2 27 059745 HEX NUT, 5/8-18 1
4 051111 ROLLER BEARING CUP 2 28 057234 MOTOR PINION SPUR 1
5 026302 DRAIN PLUG 1 29 074702 MOTOR PINION SPACER 1
6 057210 SPUR GEAR 1 30 060585 DOWEL PIN 3
7 077600 LOCK WASHER 1 31 800072 TRANSMISSION HOUSING 1
8 059680 LOCKNUT 1 32 026304 FILL PLUG 1
9 051126 BALL BEARING 1 - 500940 DRIVE WHEEL ASSY 1
10 057902 SQUARE KEY, 5/16 X 1-3/8 1 33 800025 HUB 1
11 057211 SPUR PINION 1 34 079161 RUBBER WHEEL, 10-112 IN. 1
12 057233 INTERMEDIATE GEAR 1 35 077215 LOCK WASHER, 5/8 5
13 074701 PINION SPACER 1 36 064828 HEX HEAD CAP SCREW, 5
14 051125 BALL BEARING 1 5/8-18X 1
15 074706 BEARING SPACER 1 37 042114 0-RING 1
16 036105 COVER GASKET 1 38 - DRIVE MOTOR 12V REF
17 800073 TRANSMISSION COVER 1 (FIG. 12-33)
18 077211 LOCK WASHER 3/8 11 39 026704 STREET ELBOW, 3/8 1
19 064611 HEX HEAD CAP SCREW, 7 40 076701 VENT 1
3/8-16 X 1-3/4 41 - NOT USED
20 036106 BEARING COVER GASKET 1 42 021226 TERMINAL BLOCK 1
21 051159 BEARING COVER 1 (RESISTOR SPEED
22 063555 HEX HEAD CAP SCREW, 4 CONTROL)
5/16-18 X 1 43 068185 SCREW 4
23 077210 LOCK WASHER, 5/16 4 44 077203 LOCK WASHER 4

•
24 064620 HEX HEAD CAP SCREW, 2 45 059410 HEX NUT 4
3/8-16 X 3-3/4

• PDM0495 12-15

https://forklift-manuals.jimdofree.com
 41

18

~·
13

--B
I
• 17
'
16 : I
20
19 I 1
I 18
23
• 18

•
R5389

Figure 12-9. Base and Frame

12-16 PDM0495

https://forklift-manuals.jimdofree.com
 NO.

•
INDEX PART NO . INDEX PART
NO. PART NAME REQD. NO. NO. PART NAME REQD.
NO.
1 059421 HEX NUT 1/4-20 2 14 003149 BATIERY, 200 AMP 2
2 068480 SCREW, 1/4-28 X 1 2 (PDM-30)
1
3 - LIMIT SWITCH (FIG 12-10) REF 15 501993 BASE ASSEMBLY
LOCK WASHER, 1/4 7
4 - BATIERY CHARGER REF 16 072209
30-AMP (60 HZ) (FIG 12-37) 17 059421 HEX NUT, 1/4-20 7
FLAT HEAD MACHINE SCREW 9
4 - BATIERY CHARGER REF 18 069478
30-AMP (60 HZ) (FIG 12-38) 1/4-20 X 3/4
1
4 - BATIERY CHARGER REF 19 401790 SIDE MOUNT RECEPTACLE
30-AMP (50 HZ) (FIG 12-38) 20 077031 WASHER, FLAT 2
FLAT HEAD SCREW 2 21 101078 CORD WINDER 1
5 069483
VAR OUTER MAST 1 22 111142 BASE ACCESS PLATE 1
6
500749 HYDRAULIC COMPARTMENT 1 23 005401 CONNECTOR 1
7
COVER 24 500754 CABINET DOOR ASS EM BLY 1
500743 BATIERY COMPARTMENT 2 25 059632 NUT 2
8
COVER 26 500757 SCREEN GUARD ASSEMBLY 1

9 058100 LATCH 2 27 - HYDRAULIC PANEL ASS EM BLY REF

10 071376 TRUSS HEAD SCREW 4 (TEL AND NON-TEL)

10-32 X 1/2 (FIG 12-23)
11 077208 LOCK WASHER, NO. 3/16 6 27 - HYDRAULIC PANEL ASS EM BLY REF

12 059416 HEX NUT, 10-32 6 (FFL) (FIG 12-24)

13 - LOAD WHEEL AND REF 28 068478
058107
FLAT HD SCREW, 1/4-20
LATCH DOOR SPRING
2
1
BEARING ASSEMBLY 29
(FIG 12-13) 30 111653 HANDLE 1
BATIERY, 150 AMP 2 31 072420 SCREW 4
14 003128
(PDM-20, -25) 32 077030 FLAT WASHER 4
33 069461 SCREW 2

• PDM0495 12-17

https://forklift-manuals.jimdofree.com
 1. SEE SUPPLEMENT 228 FOR TRANSISTOR
SPEED CONTROL TRUCKS SERIAL
NUMBER 338388 AND HIGHER
2. SEE SUPPLEMENT 187 FOR TRANSISTOR
SPEED CONTROL TRUCKS PRIOR TO
•
SERIAL NUMBER 338388

HARNESS f~
r('-,
---~-~
/; i '

-· I I
-- -~36 I :
-·~BLE I. I
CHARGER (REF)

~®"=:

'I ---·--r:
: J...,/l
r·+·
L··--,__ ....v··
BATT REF
! /
j.
CABLE/- :
•

41
RS390

Figure 12-10. Base and Frame- Electrical

12-18 PDM0495

https://forklift-manuals.jimdofree.com
•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 - PANEL ASSEMBLY (FIG 12·34) REF 22 057510 GROMMET 2
2 023025 HARNESS ASSEMBLY 1 23 062503 RUBBER CHANNEL AIR
3 021724 TERMINAL BOARD 1 24 504150-07 CABLE ASSEMBLY 1
4 - HARNESS ASSEMBLY (FIG 12-4) REF 25 on2o8 LOCK WASHER, #10 1
5 504154-01 CABLE ASSEMBLY 1 26 056135 CLAMP 1
6 504154-02 CABLE ASSEMBLY 1 27 076200 WRAP, ZIPPER 1
7 504158 CONNECTOR ASSEMBLY 1 28 101078 BRACKET, CORD 1
7 -* CONNECTOR ASSEMBLY 1 29 068480 SCREW, 1/4-28 X 1 2
(TRUCKS SERIAL 30 070476 SCREW, 1/4-20 X 1/2 1
NUMBER 346604 AND 31 070489 SCREW, BRASS 1
HIGHER) (FIG 12·10A) 32 on105 WASHER, BRASS 2
8 504157 CONNECTOR ASSEMBLY 1 33 068185 SCREW, #5-40 X 1-3/8 2
9 010614 STANDOFF 1 34 on2o3 LOCK WASHER, #5 2
10 111653 HANDLE 1 35 059410 NUT, HEX, #5-40 2
11 - NOT USED 36 069478 SCREW, 1/4·20 X 3/4 8
12 069483 SCREW, 1/4-20 X 3/8 2 37 504364 CLAMP AND NUT ASSEMBLY 4
13 on2o9 LOCK WASHER, 1/4 9 38 056122 CLAMP 1
14 059421 HEX NUT, 1/4·20 5 39 069470 SCREW. 10-24 X 1/2 1
15 059429 HEX NUT, 3/8-16 2 40 059418 NUT, 10..24 1
16 072211 LOCK WASHER, 3/8 2 41 ono3o WASHER 1
17 005405 BUSHING, RELIEF 2 42 056113 WIRE HARNESS TIE 4
17 019910* BUSHING, RELIEF 1 43 063478 SCREW, 1/4-20 X 3/4 1
18 020703 LIMIT SWITCH 1 44 021204 TERMINAL 1
18 020689* LIMIT SWITCH 1 45 023018 WIRE, 16 GA AIR
19 020729 DEADMAN SWITCH 1 46 021203 TERMINAL 2
- -

•
19 020690* DEADMAN SWITCH 1 LIFT MOTOR SOLENOID REF
20 800082 HORN, 12V 1 (FIG 12-22)
21 023117 CABLE ASSEMBLY 1

* TRUCKS EQUIPPED WITH COLD CONDITIONING

• PDM0495 12-19

https://forklift-manuals.jimdofree.com
 TRUCK SERIAL NUMBER
346604 AND HIGHER 41

~·

Figure 12-10A. Cold Conditioning Electrical

INDEX PART NO.

NO. NO. PART NAME REQD.
1 077200 LOCK WASHER, 1/4 2
2 070476 SCREW, 1/4-20 X 1/2 2
3 010614 STANDOFF, INSULATOR 1
4 505744 CONNECTOR ASSEMBLY 1

41
12-20 PDM0495

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•
NOTES

• PDM0495 12-21

https://forklift-manuals.jimdofree.com
 41

~·
TOUCH-UP PAINT
*901201 YELLOW
*901202 BLACK

DECAL KIT
900929

R5391

Figure 12-11. Decals, Paint and Serial Numbers

INDEX PART NO.

NO. NO. PART NAME REQD.
1 056631 BIG JOE DECAL 1
2 - NAMEPLATE, STANDARD 1
2 - NAMEPLATE, WITH 1
ATIACHMENTS
3 066050 SCREW, ROUND HEAD DRIVE 4
4 056564 CAUTION DECAL 2
5 056626 DECAL, OIL LEVEL 1
6 056625 WARNING DECAL 1
7 056613 MAST DECAL 2
8 056478 LIFT DECAL 1
9 056499 NO RIDER DECAL 1
10 056591 SAFETY DECAL 1

~·
11 056494 CAUTION DECAL 1

12-22 PDM0495

https://forklift-manuals.jimdofree.com
• SEE SUPPLEMENT 325 FOR
TRUCKS SERIAL NUMBER
353993 AND HIGHER

TYPICAL POM INSTALLATION

ADUSTABLE
STRADDLE 1.0.
MINIMUM - 38"
MAXJMl.t.l-50"

3VCTORQUE TO
f
200 FT-LSS)
4'-.!..
I
I

• R5392

Figure 12-12. Adjustable Straddle Frame

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 504848 STRADDLE 4 IN. WHEEL 2 - 504827-02 RING FORK 36 IN. LONG)) 2
SINGLE, RH (PDM-20, -25)
1 504843 STRADDLE 4 IN. WHEEL 2 - 504827-03 RING FORK 42 IN. LONG) 2
TANDEM, RH {PDM-20, -25)
2 504849 STRADDLE 4 IN. WHEEL 2 - 504827-04 RING FORK 48 IN. LONG) 2
SINGLE, LH {PDM-20, -25)
2 504844 STRADDLE 4 IN. WHEEL 2 - 504824-01 RING FORK 30 IN. LONG) 2
TANDEM, LH (PDM-30)
3 063870 HEX CAP SCREW, 3/4·10 X 2 4 - 504824-02 RING FORK 36 IN. LONG)) 2
4 077217 LOCK WASHER, 3/4 4 (PDM-30)
- 057117-01 ITA FORK 30 IN. LONG 2 - 504824-03 RING FORK 42 IN. LONG) 2
- 057117-02 ITA FORK 36 IN. LONG 2 (PDM-30)
- 057117-03 ITA FORK 42 IN. LONG 2 - 504824-04 RING FORK 48 IN. LONG) 2
- 057117-04 ITA FORK 48 IN. LONG 2 (PDM-30)
- 504827-01 RING FORK 30 IN. LONG) 2
(PDM-20, -25)

• PDM0495 12-23

https://forklift-manuals.jimdofree.com
 INDEX PART NO.
NO. NO. PART NAME REQD.
- 078409 41N. POLYURETHANE LOAD 2
WHEEL AND BEARING
ASSEMBLY (STANDARD)
- 078409 41N. POLYURETHANE LOAD 4
WHEEL AND BEARING
ASSEMBLY (PDM 30 TANDEM)
1 078435 LOAD WHEEL 1
2 051128 ROLLER BEARING 1
3 077033 SPACER 2
4 270306 AXLE 1
5 061725 SNAP RING 2
6 060974 ROLL PIN 1
7 077038 SEAL WASHER 2
8 025712 GREASE FITIING 1

- 501165 41N.POLYURETHANELOAD 4
WHEEL AND BEARING
ASSEMBLY (OPTIONAL)
R393 4-in. Load Wheel
(3 IN. WIDE STRADDLE)
1 800032 LOAD WHEEL, 2 IN. FACE 1
2 051136 BALL BEARING 2
3 077033 SPACER 2
4 050710 AXLE 1
5 061725 SNAP RING 2
6 060974 ROLL PIN 1

•
- 078256 31N.POLYURETHANELOAD 2
WHEEL AND BEARING
ASSEMBLY (OPTIONAL)
1 078230 LOAD WHEEL, 2-3/4 IN. FACE 1
2 051130 BALL BEARING 2
RETAINERS 2
3 077033 SPACER 2
4 270306 AXLE 1
5 061725 SNAP RING 2
6 060974 ROLL PIN 1

R394 3-in. Load Wheel

Figure 12-13. Load Wheels

12-24 PDM0495
•
https://forklift-manuals.jimdofree.com
• TRUCK SERIAL NUMBER
344859 AND HIGHER

I
3 I
'..J

R5355
5

Figure 12-14. Caster Wheel Assembly

•
INDEX PART NO.
NO. NO. PART NAME REQD.
- 901610 CASTER AND WHEEL ASSY 2
1 077082 CASTER MOUNTING 4
SPACERS
2 901612 AXLE AND NUT 1
3 901611 WHEEL AND BEARING 1
ASSEMBLY
4 901621 AXLE INSERT (BUSHING) 2
5 901613 THREAD GUARD 2

• PDM0495 12-25

https://forklift-manuals.jimdofree.com
~-~~ -------- --~- - - - -
 TRUCK SERIAL NUMBER
PRIOR TO 344859

R5393

Figure 12-15. Center Wheels Assembly

INDEX PART NO.

•
NO. NO. PART NAME REQD.
- 901100 CASTER AND WHEEL ASSY 2
1 901103 AXLE 1
2 901101 WHEEL ASSEMBLY 1
3 051152 BEARING 2
3 901102 BUSHING 1

41
12-26 POM0495

https://forklift-manuals.jimdofree.com
•
-~/'0
/-~ 12
/ 10
11

13 22

!7 19 L~
CAR
AGE
TO
OUTER

/[t
MAST
J--13
18 17=:::.,..--ls
14__...
_,/
3 I /
,
v'
/
15:1.

•
/
, 16 I
/
/

/I

k2o
.__II
21
R1555

Figure 12-16. Standard Masts (Nontelescopic}

INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 063709 HEX HEAD CAP SCREW 1 13 402034 LIFT CHAIN (LIFT HEIGHT 60 1N., 2
2 077213 LOCK WASHER, 112 1 CHAIN LENGTH 5Q-112 IN.
3 059545 JAM NUT, 5/8-18 2 ADJUSTABLE STRADDLE
4 057756 RAM HEAD 1 54-1/21N.
5 051120 BEARING 2 14 402051 ADJUSTING BOLT 2
6 074251 SHEAVE 2 15 077215 LOCK WASHER, 5/8 2
7 077022 FLAT WASHER 2 16 059445 HEX NUT, 5/8-18 2
8 061727 RETAINING RING 2 17 060402 COTTER PIN, 1/16 X 3/8 4
9 025712 GREASE FITTING 4 18 402055 CLEVIS PIN, 0.200 DIA. X 1 4
10 101098 CYLINDER CLAMP 1 19 VAR OUTER MAST 1
11 077211 LOCK WASHER, 3/8 5 20 077076 FLAT WASHER 1-112 X 13/32 X7 1

•
12 059429 HEX NUT 3/8-16 2 21 064605 HEX HEAD CAP SCREW, 1
3/8-16 X 1, HEAT TREATED
22 - DECAL (FIG 12-11) REF

PDM0495 12-27

https://forklift-manuals.jimdofree.com
 41
18

17 !I/19
20

~ .dJ ~21
~l."~'
22 26
23
// : 9
/
/
/
/

10

7~
31
2
LIFT
CARRIAGE

II

R1556

Figure 12-17. Standard Masts {Telescopic)

12-28 PDM0495
•
https://forklift-manuals.jimdofree.com
 INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.

•
1 077076 FLAT WASHER 1-1 f.2 X 13/32 X 7 1 19 077213 LOCK WASHER, 1f.2 1
2 077211 LOCK WASHER, 3/8 5 20 501290 RAM HEAD 1
3 064605 HEX HEAD CAP SCREW, 1 21 051120 BEARING 2
3/8-16 X 1, HEAT TREATED 22 074251 SHEAVE 2
- 500166 ROLLER ASSEMBLY 2 23 077022 FLAT WASHER 2
4 243401 ROLLER 1 24 059545 JAM NUT, 5/8-18 2
5 051145 BEARING 2 25 191089 STOP BLOCK 2
6 053012 THRUST WASHER, 3/32 THK. AIR 26 061727 RETAINING RING 2
6 053013 THRUST WASHER, 1/8 THK. AIR 27 077215 LOCK WASHER, 5/8 2
6 053014 THRUST WASHER, 5/32 THK. 4 28 059421 HEX NUT 4
6 053015 THRUST WASHER, 3/16 THK. 2 29 402034 LIFT CHAIN 2
7 064607 HEX HEAD CAP SCREW, 4 LIFT HEIGHT 106 IN.,
3/8-16 X 1-1/4 82-1/2 IN. WITH ADJ
- 500167 ROLLER ASSEMBLY 2 STRADDLES 86-3/4 IN
8 401046 ROLLER 1 LIFT HEIGHT 130 IN.,
051145 BEARING 1 107-11.2 IN. WITH ADJ
9 025712 GREASE FITTING 4 STRADDLES 111-3/41N
10 239520 CLAMP BAR 1 LIFT HEIGHT 154 IN.,
11 060402 COTTER PIN, 1/16 X 3/8 4 131-3/4 IN. WITH ADJ
12 402055 CLEVIS PIN, 0.200 DIA. X 1 4 STRADDLES13~3~1N
13 069483 FLAT HEAD SCREW 4 30 VAR OUTER MAST 1
14 402051 ADJUSTING BOLT 2 31 VAR INNER MAST 1
15 0772CYiiJ LOCK WASHER, 1/4 2 32 063607 HEX HEAD CAP SCREW, 2
16 059445 HEX NUT, 5/8-18 2 3/8-16 X 1/4
17 100016 SPACER 2 33 077211 LOCK WASHER, 3/8 5
18 0647CYiiJ SCREW, HEX HEAD, 1 34 313001 ANGLE 1
1/2-13 X 1-11.2 35 236001 SPINDLE 4

• PDM0495 12-29

https://forklift-manuals.jimdofree.com
 •
TO
OUTER
MAST
~24

13------e. L- 19

13~
c
_ '~
22_...-tu:T
22
I..IFT
YI..INOER
r

20~
23

R1557

Figure 12-18. Inner and Outer Masts - Full Free Lift

•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 053012 THRUST WASHER, 3/32 THK. AIR 10 191089 STOP BLOCK 2
1 053013 THRUST WASHER, 1/8 THK. AIR 11 077200 LOCK WASHER, 1/4 4
1 053014 THRUST WASHER, 5/32 THK. AIR 12 059421 HEX NUT, 1/4-20 4
1 053015 THRUST WASHER, 3/16 THK. AIR 13 402055 CLEVIS PIN, 0.200 DIA. X 1 4
- 500107 ROLLER ASSEMBLY 2 14 800246 YOKE SHEAVE 2
2 051145 BEARING 2 15 061729 EXTERNAL RETAINING RING 2
3 401046 ROLLER 1 16 401639 SHEAVE PIN 2
- 500166 ROLLER ASSEMBLY 2 17 065555 CAP SCREW, 5/16·18 4
4 051145 BEARING 1 18 289205 HEAVY DUTY SHEAVE 2
243401 ROLLER 1 19 402051 ADJUSTING BOLT 2
5 025712 GREASE FITTING 4 20 077215 LOCK WASHER, 5/8 2
6 077076 FLAT WASHER 1-1/2 X 13/32 X7 2 21 059545 JAM NUT, 5/8-18 2
7 077211 LOCK WASHER, 3/8 5 22 060402 COTTER PIN, 1/16 X 3/8 4
8 064605 HEX HEAD CAP SCREW, 2 23 059445 HEX NUT, 3/4-16 2
3/8-16 X 1, HEAT TREATED 24 402034 LIFT CHAIN AIR
9 069483 FLAT HEAD SCREW 4 25 236001 SPINDLE 4

12-30 PDM0495
•
https://forklift-manuals.jimdofree.com
• SEE FIGURE 12-12
FOR ADJUSTABLE
STRADDLE OPTIONS

J
:~~
10 ....
13...........--TI
V

8
..-

\ I

R1736

• INDEX
NO.
PART
NO.
Figure 12-19. Lift Carriage (Shaft Type) Telescopic and Nontelescopic and FFL

PART NAME
NO.
REQD.
INDEX
NO.
PART
NO. PART NAME
NO.
REQD.
1 504539..()6 LIFT CARRIAGE ASSEMBLY 1 5 053015 THRUST WASHER, 3/16 THK. AIR
1-1/41N SHAFT, TELESCOPIC - 500167 ROLLER ASSEMBLY 4
1 504539.05 LIFT CARRIAGE ASSEMBLY 1 (TELESCOPIC)
1-1/4 IN SHAFT, 6 051145 BEARING 1
NONTELESCOPIC 7 401046 ROLLER 1
1 504539.01 LIFT CARRIAGE ASSEMBLY 1 - 500166 ROLLER ASS EM BLY 2
1-1/4 IN SHAFT, (NONTELESCOPIC)
FULL FREE LIFT 6 051145 BEARING 1
2 276604 FORK SHAFT, 1-1/4 INDIA. 1 7 243401 ROLLER 1
3 061729 SNAP RING 2 8 025712 GREASE FITTING 4
4 507119-02 FORK, 36 IN. (PDM 20 & 25) 2 9 402034 LIFT CHAIN AIR
4 507119-03 FORK, 42 IN. (PDM 20 & 25) 2 10 402051 ADJUST! NG BOLT 2
4 507119-04 FORK, 48 IN. (PDM 20 & 25) 2 11 060402 COTTER PIN, 1/16 X 3/8 2
4 500330 FORK, 36 IN. (PDM 30) 2 12 402055 CLEVIS PIN, 0.200 DIA. X 1 2
4 500331 FORK, 42 IN. (PDM 30) 2 13 059545 JAM NUT, 5/8-18 2
4 500332 FORK, 48 IN. (PDM 30) 2 14 077215 LOCK WASHER, 5/8 2
5 053012 THRUST WASHER, 3/32 THK. AIR 15 059445 HEX NUT, 5/8-18 2
5 053013 THRUST WASHER, 1/8 THK. AIR 16 500126 SPINDLE, 1-1/41N. 4
5 053014 THRUST WASHER, 5/32 THK. AIR

• PDM0495 12-31

https://forklift-manuals.jimdofree.com
 41

R953
•
Figure 12-20. ITA Lift Carriages {Optional)

41
12-32 PDM0495

https://forklift-manuals.jimdofree.com
 INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.

•
1 VAR LIFT CARRIAGE ASSEMBLY 1 8 053013 THRUST WASHER, 1/8 THK. AIR
2 077215 LOCK WASHER, 5/8 2 8 053014 THRUST WASHER, 5/32 THK. AIR
3 063820 HEX HEAD CAP SCREW, 2 8 053015 THRUST WASHER, 3/16 THK. AIR
5/8-11 X 1-1/4 9 077215 LOCK WASHER, 5/8 2
4 057115 FORK ASSEMBLY, 2 10 059445 HEX NUT, 5/8-18 2
1-1/2 X4 X30 IN 11 059545 JAM NUT, 5/8-18 2
4 057172 FORK ASSEMBLY, 2 12 402055 CLEVIS PIN, 0.200 DIA. X 1 2
1-1/2 X4 X361N 13 060402 COTTER PIN, 1/16 X 3/8 2
4 057173 FORK ASSEMBLY, 2 14 402051 ADJUSTING BOLT 2
1-1/2 X4 X421N 15 402034 LIFT CHAIN AIR
4 057174 FORK ASSEMBLY, 2 16 503752 LOAD BACKREST, 1
1-1/2 X4 X481N 1-1/2 IN FORKS 28 IN. WIDE
5 025712 GREASE FITTING 4 16 401527 FORK RETAINER BAR 2
- 500167 ROLLER ASS EM BLY 4 (TRUCKS WITHOUT LOAD
(TELESCOPIC) BACKREST)
6 051145 BEARING 1 17 077215 LOCK WASHER, 5/8 2
7 401046 ROLLER 1 18 063820 HEX HEAD CAP SCREW, 2
- 500166 ROLLER ASSEMBLY 4 5/8-11 X 1-1/4
(NONTELESCOPIC) 19 077066 ROUND WASHER 4
6 051145 BEARING 1 20 50n39 ITA FORK HINGE KIT 2
7 243401 ROLLER 1 21 500126 SPINDLE, 1-1/41N. 4
8 053012 THRUST WASHER, 3/32 THK. AIR

• POM0495 12-33

https://forklift-manuals.jimdofree.com
 u
I
7

I
I

~13
I

~
10

I
o-14 9
'' II

&--1s
R461
~20 ~·
Figure 12-21. Lift Control Valve Assembly
504216-02- Standard
503209- Cold Conditioning
INDEX VALVE PART NUMBER NO.
NO. 504216-02 503209 PART NAME REQD.
1 240501 240501 VALVE BODY 1
2 042104 042104 0-RING 1
3 304611 304611 RELEASE CAM 1
4 052803 400045 SWITCH BRACKET 1
5 070475 070475 MACHINE SCREW, 1/4-20 X 3/8 2
6 057952 057952 KNOB 1
7 057702 057701 LEVER 1
8 060937 060937 ROLL PIN 2
9 059530 - JAM NUT, 3/8-24 2
9 - 059529 JAM NUT, 3/8-16 2
10 257401 400097 VALVE CLAMP 1
11 075015 075015 HANDLE RETURN SPRING 1
12 500942 504365 SWITCH ASSEMBLY 1
13 060608* 060608* VALVE PIN, 5/32 X 1-1/4 1
14 051404* 051404* CHECK BALL, 3/8 1
15 075052* 075052* COMPRESSION SPRING 1
16 059675 - SWITCH ADJUSTING NUT 2
17 063478 063478 HEX HEAD CAP SCREW, 1/4-20 REF
18 077209 077209 LOCK WASHER REF
19 026303 026303 PLUG 1
20 026500 026500 REDUCER, 3/8 TO 1/4 NPT REF

* PART OF REPAIR KIT 900132

~·
12-34 PDM0495

https://forklift-manuals.jimdofree.com
• /~· .._13
7

r
i

I
-j
./ ~

7~,
J) :_., 12

ii
_ /IJ 8

j
• /

·, ..... _

--....____
R5421

Figure 12-22A. Hydraulic Installation (TEL AND NON-TEL)

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 - HYDRAULIC PANEL ASSEMBLY REF 8 282500 TUBING, VINYL, 1/4 OD- 1/8 ID AIR
(FIG 12-23, 12-24) g 057511 GROMMET 1
2 063603 SCREW, 3/8-16 X 3/4 2 10 057508 GROMMET 1
3 077211 LOCK WASHER, 3/8 2 11 077056 WASHER, FLAT, 3/8 2
4 025516 ELBOW, SWIVEL, 3/8 1 12 VAR LIFT CYLINDER REF
5 047110 VALVE, FLOW CONTROL 1 (FIG 12-27 & 12·28)

•
6 025538 ELBOW, go•, 3/8 MALE 1 13 02041g LIFT MOTOR SOLENOID 1
7 025501 ELBOW, 1/4, NPT TUBE, go• 2

PDM0495 12-35

https://forklift-manuals.jimdofree.com
 41

11

~·

R5811

Figure 12·228. Hydraulic Installation (FFL)

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REOD. NO. NO. PART NAME REQD.
1 - HYDRAULIC PANEL ASSEMBLY REF 9 057508 GROMMET 1
{FIG 12-24) 10 026203 PLUG 1
2 063603 SCREW, 3/8-16 X 3/4 2 11 VAR LIFT CYLINDER REF
3 077211 LOCK WASHER, 3/8 2 (FIG 12-27 & 12-28)
4 026711 ELBOW,45° 1 12 077056 WASHER, FLAT, 3/8 2
5 026109 NIPPLE 1 13 056116 CLAMP 1
6 026504 REDUCER 2 14 077030 WASHER 1
VALVE, FLOW CONTROL 1 15 077209 LOCK WASHER 1

•
7 047107
8 025513 ELBOW,45° 1 16 063495 SCREW, 1/4-20 X 1/2 1

12-36 PDM0495

https://forklift-manuals.jimdofree.com
• EARLIER MODELS WITH NPT PORTS

28
5

26

~
r-
1
I
I
I
I
,.,..)
/

28
21 21

2
9
8

• R5436

Figure 12-23. PDM Hydraulic Panel Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.

- 504159 PDM HYDRAULIC PANEL REF 13 026139 HOSE NIPPLE 1

ASEMBLY 14 056118 SPRING HOSE CLAMP 2
1 500590 HYDRAULIC PANEL 1 15 290003 VINYL TUBING 1
2 500689 RESERVOIR 1 16 026131 CLOSE NIPPLE, 1/4 X 1 NPT 1
3 - PUMP AND MOTOR REF 17 035106 FILTER 1
ASSEMBLY 18 026708 ELBOW, 90° 1
(FIG 12-29, 12-30) 19 026104 CLOSE NIPPLE, 1/4 NPT 1
4 - LIFT CONTROL VALVE REF 20 027102 TEE, 1/4 NPT 1
ASSEMBLY WITH SWITCH 21 038110 HOSE ASSEMBLY 1
(FIG 12-21) 22 026302 MAGNETIC PLUG, 3/8 NPT 1
5 077477 PHILLIPS RD HD SCREW 4 23 500422 BREATHER CAP AND 1
1/4-20 X 5/8 DIPSTICK ASSEMBLY
6 026704 ELBOW, STREET, 1 24 - NOT USED
3/8 NPT, 90° 25 069712 FLAT HD SCREW, 3/8-16 X 3/4 2
7 026128 NIPPLE, HOSE, 3/8 1 26 069478 FLAT HD SCREW, 1/4-20 X 3/4 2
8 056110 CLAMP 2 27 059421 HEX NUT, 1/4-20 2
9 278804 VINYL TUBING 1 28 077209 LOCK WASHER, 6
10 026500 PIPE REDUCER, 1 - - LIFT MOTOR SOLENOID REF

•
3/8 X 1/4 NPT (FIG 12-22)
11 025313 SWIVEL CONNECTOR 1 - 900893 HYDRAULIC OIL (QUART)
12 038104 HOSE ASSEMBLY 1 - 900855 HYDRAULIC OIL (GALLON)

PDM0495 12-37

https://forklift-manuals.jimdofree.com
 LATER MODELS WITH SAE PORTS

RS437

Figure 12-24.
21--l

PDM Hydraulic Panel Assembly

•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 504200 PDM HYDRAULIC PANEL REF 13 056118 SPRING HOSE CLAMP 2
ASEMBLY 14 290005 VINYL TUBING 1
1 500690 HYDRAULIC PANEL 1 15 026131 CLOSE NIPPLE, 1/4 X 1 NPT 1
2 500689 RESERVOIR 1 16 035106 FILTER 1
3 - PUMP AND MOTOR REF 17 025128 ADAPTER 1
ASSEMBLY 18 026109 NIPPLE, HOSE, 3/8 1
(FIG 12·29, 12-30) 19 027107 TEE, 3/8 NPT 1
4 - LIFT CONTROL VALVE REF 20 504199-12 HOSE ASSEMBLY 1
ASSEMBLY WITH SWITCH 21 026302 MAGNETIC PLUG, 3/8 NPT 1
(FIG 12-21) 22 500422 BREATHER CAP AND 1
5 077477 PHILLIPS RD HD SCREW 4 DIPSTICK ASSEMBLY
1/4-20 X 5/8 23 069712 FLAT HD SCREW, 3/8·16 X 3/4 2
6 026704 ELBOW, STREET, 1 24 069478 FLAT HD SCREW, 114-20 X 3/4 2
3/8 NPT, 90° 25 059421 HEX NUT, 1/4-20 2
7 026128 NIPPLE, HOSE, 3/8 1 26 077209 LOCK WASHER, 6
8 056110 CLAMP 2 - - LIFT MOTOR SOLENOID REF
9 278804 VINYL TUBING 1 (FIG 12·22)
10 025107 SWIVEL CONNECTOR 1 - 900893 HYDRAULIC OIL (QUARn AR
-

•
11 504199-01 HOSE ASSEMBLY 1 900855 HYDRAULIC OIL (GALLON) AR
12 025113 STRAIGHT CONNECTOR, 1/4 1

12-38 PDM0495

https://forklift-manuals.jimdofree.com
• NOTES

• PDM0495 12-39

https://forklift-manuals.jimdofree.com
 •

R480

Figure 12-25. Remote Installation

•
INDEX PART NO.
NO. NO. PART NAME REQD.
1 017800 RECEPTACLE-FEMALE 1
2 068177 SCREW 5-40 X 3/8 2
3 on203 LOCK WASHER #5 2
4 059410 HEX NUT, 5-40 2
- 501736 CONTROL STATION ASS EM BLY 1
5 800130 CONTROL BOX 1
6 058501 MAGNET 1
7 on20s LOCK WASHER, 1/4 1
8 059421 HEX NUT, 1/4-20 1
9 3140032 COIL CORD, 3 FEET 1
10 017801 MALE PLUG 1
11 052905 STRAIN RELIEF 1

12-40 PDM0495
•
https://forklift-manuals.jimdofree.com
•
NOTES

• PDM0495 12-41

https://forklift-manuals.jimdofree.com
 504363.01
LIFT ONLY IN HEAD

••
\ \ /~
1 3 2

504363.02 (RES) LIFT & LOWER IN HEAD

504363.03 (TRANS)

7C2REO'Di

~) W/TRANSISTOA
sa 5

2
9

~
14 •
504363-o4 (RES)
504363-05 (TRANS)

14
3
2

504363.06 (RES)
504363-07 (TRANS)
RS426

Figure 12-26. Remote Installation (Continued)

12-42 PDM0495
•
https://forklift-manuals.jimdofree.com
•
504363-01 504363-02 504363-03 504363-04 504363-05 504363-06 504363-07
LIFT LIFT&LOWER LIFT &LOWER LIFT&LOWER LIFT&LOWER UFT&LOWER LIFT&LOWER
ITEM IN HEAD IN HEAD IN HEAD BOX BOX IN HEAD& IN HEAD&
ONLY (RES) (TRANS) (RES) (TRANS) BOX(RES) BOX (TRANS)
1 021204(1) 021204(4) 021204(4) 021204(2) 021204(2) 021204(4) 021204(4)
2 021203 (1) 021203 (1) 021203 (1) 021203 (1) 021203 (1) 021203 (2) 021203 (2)
3 023018 023018 023018 023018 023018 023018 023018
4 048132 048132 048132 048132 048132 048132
5 021207 021207 021207 021207 021207 021207
6 504116 504116 504116
7 005422 005422 005422
8 017800 017800 017800 017800
9 021236 {3) 021236 {3) 021236 {3) 021236 {3)
10 005433 005433 005433 005433
11 0681n {2) 068177 {2) 068177 {2) 0681n {2)
12 077203 {2) on203{2) 077203 (2) 077203 {3)
13 059410 {2) 059410 {2) 059410 (2) 059410 (2)
14 501736 501736 501736 501736

• PDM0495 12-43

https://forklift-manuals.jimdofree.com
 PACKING KIT
CONTAINS
ITEM QTY
41
2 1
4 1
7 1
9 1

I
I
L _ _j
I

R810

Figure 12-27. Lift Cylinder (TEL AND NON-TEL)

INDEX

-
NO.

2
3
1
601NCH
LIFT
503568.()1

049509*
800024
-
1061NCH
LIFT
503568.()5
-
049509*
800024
1301NCH
UFT
503568-07
-
049509*
800024
1541NCH
LIFT
503568-11
-
049509*
800024
PART NAME
LIFT CYLINDER ASSY
TUBEASSY
WIPER RING
GLAND NUT
NO.
REQD.
1
1
1
1
•
4 042113* 042113* 042113* 042113* TOPO-RING 1
5 -
300501
-
300501
- - RAM ROD 1
6 300501 300501 RAM STOP 1
7 042105* 042105* 042105* 042105* BOTTOM 0-RING 1
8 045102 045102 045102 045102 PISTON 1
9 043108* 043108* 043108* 043108* PACKING ASSY 1
10 077005 077005 onoo5 onoo5 FLAT WASHER 1
11 059547 059547 059547 059547 JAM NUT, 3/4-16 1
12 061023 061023 061023 061023 ROLL PIN, 5/16 X 3/4 1
13 077036 077036 on036 on036 FLAT WASHER AIR

* Included in Packing Kit No. 900142.

12-44 PDM0495
•
https://forklift-manuals.jimdofree.com
•
NOTES

• PDM0495 12-45

https://forklift-manuals.jimdofree.com
 .----~\_.•....-11 PISTON
ROO
/ ~
/
I
~12

TOOL
900931

14

CYUNCER

PACKING KIT
CONTAINS

•
ITEM QTY
5 1
6 1
7 1
8 1
10 1
17 2
19 2
21 2
R1583

Figure 12-28. Lift Cylinders (FFL)

12-46 PDM0495
•
https://forklift-manuals.jimdofree.com
•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REOD.
- 503996..01 FFL CYLINDER ASSEMBLY 1 11 059128 FLEXLOC LOCK NUT 3
106 IN. LIFT HEIGHT 12 401642 PISTON, 2.5 DIA. 1
- 503996..02 FFL CYLINDER ASSEMBLY 1 13 503992..01 CYLINDER ROD, 106 LIFT HT 1
130 IN. LIFT HEIGHT 13 503992..02 CYLINDER ROD, 130 LIFT HT 1
1 503995..01 FFL CYLINDER WELDMENT 1 14 401641 WEAR RING 1
106 IN. LIFT HEIGHT 15 061824 SNAP RING RETAINER 2
1 503995..02 FFL CYLINDER WELDMENT 1 16 401584 CYLINDER HEAD, 2.00 DIA. 2
130 IN. LIFT HEIGHT 17 049517..01* . CYLINDER HD WIPER RING 2
2 026308 SQUARE HD PLUG, l/4 NPT 1 18 029103 BREATHER PLUG 2
3 061825 SNAP RING RETAINER 1 19 043130* 'U' CUP SEAL 2
4 401645 CYLINDER HEAD, 2.50 DIA. 1 20 401384 PISTON, 2.00 DIA. 2
5 042150* 'O'RING 1 21 042136* 'O'RING 2
6 042151* BACK-UP RING 1 22 401646 WEAR RING 2
7 049517..02"~ . HYDRAULIC CYLINDER 1 23 401642..01 CYLINDER ROD, 106 LIFT HT 2
WIPER RING 23 401642-Q2 CYLINDER ROD, 130 LIFT HT 2
8 043132* 'U' CUP ROD SEAL 1 - 055706 LOCTITE 222 ADHESIVE AIR
9 401652 CYLINDER BASE, 2.50 DIA 1 - 900893 HYDRAULIC OIL (QUART) AR
10 042149* 'O'RING 1 - 900855 HYDRAULIC OIL (GALLON) AR

* INCLUDED IN PACKING KIT PART NUMBER 900949

SPECIFY TRUCK MODEL NUMBER, UFT HEIGHT,
AND SERIAL NUMBER WHEN ORDERING UFT CYLIN-
DER PARTS•

• PDM0495 12-47

https://forklift-manuals.jimdofree.com
 SEE SUPPLEMENT
333 FOR ADDITIONAL
INFORMATION
SERIAL NUMBERS
341476 AND HIGHER 41

NOTE: The only replaceable parts in

the motor are brushes #2, springs
#3 and bearings #4 & #1 0.

R5264

Figure 12-29. Pump and Motor Assembly 016936

•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.

- 016936 PUMP AND MOTOR ASSEMBLY 1 8 901'524 COUPLING 1

1 901528 DC MOTOR 12V 2 TERMINAL 1 9 901525 PUMP SHAFT SEAL 1
2 901529 DC MOTOR BRUSH KIT 1 10 901532 DRIVE END BEARING 1
3 901534 BRUSH SPRING KIT 1 11 048132 REMOTE VALVE (OPTIONAL) 1
4 900945 COMMUTATOR END 1 12 901530 PUMP 1
BEARING 13 901526 PUMP BOLTS 2
5 901521 MOTOR ADAPTER 1 - - LIFT MOTOR SOLENOID REF
6 901522 PUMP ADAPTER 1 (FIG 12-22)
7 901523 PUMP ADAPTER BOLTS 4

12-48 PDM0495
•
https://forklift-manuals.jimdofree.com
• USED ON TRUCKS PRIOR TO
SERIAL NUMBER 341476

/
/
/
/
/
/

5~1 v

•
R1666

Figure 12-30. Hydraulic Pump

INDEX PART NO.

NO. NO. PART NAME REQD.

- 016912 PUMP AND MOTOR ASSEMBLY 1

(TRUCKS SERIAL NUMBER
333620 THRU 333652 AND
333890 THRU 341475)
- 016922 PUMP AND MOTOR ASSEMBLY 1
(TRUCKS SERIAL NUMBER
333653 THRU 333889)
1 900896-03 PUMP 1
2 036107 GASKET 1
3 056353 COUPLING 1
4 077210 LOCK WASHER 4
5 063553 HEX HD CAP SCREW 4
6 - PUMP MOTOR 1
(FIG 12-31, 12-32)
- - LIFT MOTOR SOLENOID REF
(FIG 12-22)

** FOR REMOTE UNITS, REMOVE CAP A AND

INSTALL 048132 SOLENOID VALVE .

• PDM0495 12-49

https://forklift-manuals.jimdofree.com
 SERIAL NUMBERS
333620 THRU 333652 AND
333890 THRU 341475
41
1
I
I
I
I
I
I 10

I
) II
/

J~~
/
/
/
/
/

@ ~· / / / /

/
/
/
/ ~\ 17 13
14

18
(
12
I
I
I
I
I ./
v/
19 ~
R1990

Figure 12-31. Pump Motor 905035

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 905035 MOTOR ASSEMBLY 1 11 905033 PROTECTIVE CAP 1
1 905036 FIELD COIL 12 VDC 1 12 905034 COMMUTATOR END 1
2 905048 ARMATURE 1 13 905037 RETAINER 1
3 - NOT USED 14 905038 FILLISTER HEAD SCREW 2
4 905045 PIN 1 15 905039 FILLISTER HEAD SCREW 4
5 905051 FLAT HEAD SCREW 4 16 905040 SPRING LOCK WASHER 4
6 905052 RETAINER 1 17 905041 FILLISTER HEAD SCREW 4
7 900495 BEARING 2 18 905042 BRUSH HOLDER 1
8 905030 SPRING WASHER 1 19 905043 SPIRAL SPRING 4
9 905031 RETAINER 1 20 905044 CARBON-BRUSH SET 1
10 905032 TERMINAL STUD PACKAGE 1

12-50 PDM0495
•
https://forklift-manuals.jimdofree.com
• SERIAL NUMBERS
333653 THRU 333889

• R3087

Figure 12-32. Pump Motor 904140

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 904140 MOTOR ASSEMBLY 1 7 904170 HEAD, COMMUTATOR END 1
1 900855 DRIVE END HEAD 1 8 904171 BRUSH PLATE ASSEMBLY 1
2 900495 SEALED BALL BEARING 2 9 003714 BRUSH SPRING SET 1
3 904172 SPACER ARMATURE D.E. 2 10 - BRUSH PLATE 1
4 904166 ARMATURE 1 11 904167 BRUSH SET 1
5 904175 SPRING WASHER 1 12 904168 FIELD COIL PACKAGE 1
6 904174 THRU BOLT AND 1 13 904173 TERMINAL STUD PACKAGE 1
INSULATION PACKAGE

• PDM0495 12-51

https://forklift-manuals.jimdofree.com
 6
7

9
•
3

l~
12
i
I
I
I
I
I

•
I
I
I
I /
v/

R1189

Figure 12-33. Drive Motor 016042

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 016042 MOTOR ASSEMBLY 1 11 900136 SPRING, BRUSH 1
1 901238 SPACER DRIVE END 1 12 901248 BRUSH HOLDER 1
2 901239 SEAL, SHAFT, DRIVE END 1 13 900787 BRUSH 1
3 901240 HEAD ASSEMBLY, DRIVE END 1 14 901254 FIELD COIL SET 1
4 901241 BEARING, BALL, SEALED 1 - 901250 CONNECTOR AND STUD 1
5 901242 RETAINER, BEARING 1 ASSEMBLYA2
6 901243 ARMATURE 1 - 901251 CONNECTOR AND STUD 1
7 901244 BEARING, BALL, SEALED 1 ASSEMBLYA1
COMMUTATOR END 15 901253 POLE SHOE, SCREW 8
8 901245 WASHER, SPRING 1 5/16-24 X 7/8 FL HD
COMMUTATOR END 16 901252 TERMINAL KIT 2
BEARING (HARDWARE INCL)
9 901246 BAND, COVER 1 - 901257 SPACER, BRUSH HOLDER 4
10 901247 HEAD ASSEMBLY, 1
COMMUTATOR END

12-52 PDM0495
•
https://forklift-manuals.jimdofree.com
•
NOTES

• PDM0495 12-53

https://forklift-manuals.jimdofree.com
 1. SEE SUPPLEMENT 228 FOR TRANSISTOR TRUCKS
SERIAL NUMBER 338388 AND HIGHER.
2. SEE SUPPLEMENT 187 FOR TRANSISTOR TRUCKS
PRIOR TO SERIAL NUMBER 338388.

TERMINAre:IIATT NEG
39lERMINATION P\IMP NEG
F2CABLE CHARGER NEG
3 39 lERMINATION
A2 CABLE
2

42

10
•
R5422

Figure 12-34. Contactor Panel Assembly

12-54 PDM0495

https://forklift-manuals.jimdofree.com
•
INDEX PART NO. INDEX PART NO •
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 504659 PANEL ASS EM BLY 1 23 018907 ELECTRICAL BRAKE 1
1 504657 BASE PLATE 1 RESISTOR
2 401181 BUS BAR 3 24 - CONTACTOR, SINGLE 3
3 070491 SCREW, RH HD, 8-32 X 1 10 POLE (FIG 12-46)
4 077205 SPLIT LOCK WASHER, #8 10 25 008906 300 AMP FUSE 1
5 - CONTACTOR,DOUBLE 2 26 056507 FUSE, DECAL, 300 AM, 1
POLE (FIG 12-47) 0.020ALUM.
6 504150-16 CABLE, ASSY. 1 27 008917 FUSE, 40 AMP, 1
7 068179 SCREW, RD HD, #5-40 X 5/8 3 DYNAMIC BRAKE
8 077203 LOCK WASHER 5 28 056515 DECAL FUSE, DYNAMIC 1
9 059410 HEX NUT 5 BRAKE
10 021226 TERMINAL BLOCK, 1 29 077105 FLAT BRONZE WASHER 8
SPADETYPE 30 0772C:S LOCK WASHER, 1/4 12
11 071376 PAN HEAD SCREW, 1Q-32 X 112 2 31 075620 STUD-THREADED, BRASS, 2
12 077208 SPLIT LOCK WASHER, 3/16 2 1/4-20 X 1-1/4
13 250716 SPEED CONTROL BRACKET 2 32 070488 SCREW, RH HD, 1/4-20 X 3/8 6
14 018904 SPEED CONTROL RESISTOR 1 33 010614 STAND-OFF 4
15 504150-15 CABLE, ASSY. 2 34 056504 DECAL, FUSE, 15A 1
16 021221 TERMINAL FOR USE WITH 3 35 504658 CABLEASSY 1
SPD CONTROL RESISTOR 36 008910 15 AMP FUSE 1
17 021238 TERMINAL RING TYPE, 1/4 4 37 008904 FUSE HOLDER 1
18 504150-10 CABLE, ASSY. 1 38 070475 SCREW, FD HD, 1/4-20X3/8 4
19 023026 WIRE, 10 GA. WHITE AIR 39 504150-05 CABLE, ASSY. 2
20 021237 TERMINAL RING 2 40 504150-02 CABLE, ASSY. 1
21 068177 SCREW, RD HD, #5-40 X 3/8 2 41 504150-04 CABLE, ASSY. 1
22 077007 WASHER 5/32' O.D. X5/16' 2 42 023132 WIRE HARNESS ASSY 1

•
I.D. 20 GAUGE 43 059421 NUT-HEX, 1/4-20 2

NOTE: FOR A COMPLETE SET OF CONTACTOR 11PS

ORDER PART NUMBER 900531..()1 •

• PDM0495 12-55

https://forklift-manuals.jimdofree.com
 CONTACTOR TIP
KIT 900531-08 CONTAINS
ITEM QTY
41
3 1
4 1
8 1
12 1

R1865

Figure 12-35. Single Pole Contactor, 2nd Speed, 3rd Speed Dynamic Brake
•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 005658 CONTACTOR SINGLE POLE, 1 8 905029* MOVING CONTACT 1
100AMP. 12V ASSEMBLY
1 905010 BASE MOLDING 1 9 905019 ARMATURE PLATE 1
2 905024 MAGNETIC FRAME 1 10 905020 POLE PIECE 1
3 905013* BRAID ASSEMBLY 1 11 905021 COIL ASSEMBLY 12-VOLT 1
4 905025 FRONT MOLDING WITH 1 12 905022* FRONT CONTACT 1
BLOWOUT 13 905023 SPACER 1
5 905015* ARMATURE PLATE RETAINER 1 14 401181 BUS BAR (NOT PART 1
6 905016 COMPRESSION SPRING 2 OF CONTACTOR)
7 905017 SPRING STUD 1

* CONTACTOR TIP KIT 900531-QB. ONE KIT REPAIRS

ONE CONTACTOR.

41
12-56 PDM0495

https://forklift-manuals.jimdofree.com
• 3
CONTACTOR
TIP KIT 900531-09

ITEM
CONTAINS

5
QTY
1
1
8 1 5/SIN LG
12 1 13 1
16 1

~ 9

16 ~
"'\\\~~\
I I

• R1866

Figure 12-36. Double Pole Contactor, Forward, Reverse

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME !REaD. NO. NO. PART NAME REQD.
- 005656 CONTACTOR DOUBLE POLE, 1 9 905019 ARMATURE PLATE 1
100AMP. 12V 10 905020 POLE PIECE 1
1 905010 BASE MOLDING 1 11 905021 COIL ASSEMBLY 12-VOLT 1
2 905024 MAGNETIC FRAME 1 12 905022* FRONT CONTACT 1
3 905013* BRAID ASSEMBLY 1 13 905023 SPACER 1
4 905025 FRONT MOLDING WITH 1 14 401181 BUS BAR (NOT PART 1
BLOWOUT OF CONTACTOR)
5 905015* ARMATURE PLATE RETAINER 1 16 905026* BACK CONTACT 1
6 905016 COMPRESSION SPRING 2 17 905027 REAR MOLDING 1
7 905017 SPRING STUD 1
8 905018* MOVING CONTACT 1
ASSEMBLY

* CONTACTOR TIP KIT 900531.()9. ONE KIT REPAIRS

•
ONE CONTACTOR•

PDM0495 12-57

https://forklift-manuals.jimdofree.com
 •

13
14

' .........
7

~
RS271

Figure 12-37. "SMART" Charger 00497~1

5

•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 004975-01 SMART CHARGER 1 10 907111 CONTROL CARD 1
1 900467 DIODE ASSEMBLY 1 (CIRCUIT BOARD)
2 900656 FUSE NON-45 1 11 900465 CAPACITOR 1
3 900887 TRANSFORMER 1 12 900466 CAPACITOR STRAP 1
4 900379 PILOT LIGHT 1 13 900655 FUSE CLIP 1
5 900462 AMMETER 1 14 900654 INSULATOR PLATE 1
6 052905 STRAIN RELIEF 1 15 900653 NYLON STANDOFF 1
7 005802 ACCORD 1 16 907058 FUSE HOLDER 1
8 907077 TRIAC 1 17 900847 FUSEAGC10 1
9 907078 TRANSFORMER 1
(CIRCUIT BOARD)

12-58 PDM0495
•
https://forklift-manuals.jimdofree.com
• USED ON TRUCKS
SERIAL NUMBER
3055436 AND HIGHER

3 4
SEE SUPPLEMENT 330 FOR
TRUCKS SERIAL NUMBER
356292 AND HIGHER

13
14

11

• R543D
10

Figure 12-38. 3D-Amp Timer Battery Charger

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.

- 004950 BATTERY CHARGER ASSEMBLY 1 7 900892 AC CORD AND PLUG SET 1

(3D-AMP (60 HZ) INPUT) (120 V, 50 HZ)
- 004951 BATTERY CHARGER ASSEMBLY 1 8 900376 KNOB 1
(30-AMP (50 HZ) INPUT) 9 900529 DIAL 1
1 900467 RECTIFIER ASSEMBLY 1 10 900375 TIMER (120 V, 60 HZ) 1
900527 HEAT SINK 1 10 900749 TIMER (120 V, 50 HZ) 1
2 900656 FUSE, BUSSE, NON-45 1 11 900465 CAPACITOR 1
3 900887 TRANSFORMER 1 12 900466 BRACKET 1
(120 V, 60HZ) 13 900655 FUSE CLIP 2
3 900889 TRANSFORMER 1 14 900654 INSULATOR PLATE 1
(120 V, 50 HZ) 15 900653 NYLON STANDOFF 2
4 - CASE 1 16 907058 FUSE HOLDER 1
5 900462 AMMETER 1 17 900943 FUSE 1
6 900364 STRAIN RELIEF, ACCORD 1

•
7 005802 ACCORD AND PLUG SET 1
(120 V, 60HZ)

PDM0495 12-59

https://forklift-manuals.jimdofree.com
 41

R1517

Figure 12-39. Optional Hour Meter Switch Installation

•
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
- 504189 HOUR METER INSTALLATION 1 7 021204 TERMINAL, SLIDE CLIP, 1/4 4
1 068179 SCREW, RD HD, #5-40 X 5/8 3 8 010610 PAD, INSUL, DIODE 1
2 077203 LOCK WASHER 5 9 005987 DIODE ASSEMBLY 1
3 059410 HEX NUT 5 10 005976 DIODE 3
4 015604 METER, HOUR 1 - 010606 MOUNTING PANEL 1
5 068177 SCREW, RD HD, #5-40 X 3/8 2 - 023018 WIRE, BLACK, #16 AIR
6 005422 CONNECTOR, INLINE, INSUL 4 STRANDED

12-60 PDM0495
•
https://forklift-manuals.jimdofree.com
• T0300AMP
FUSE AND
BATTERY
CONNECTOR
{Qo!)::::l---c:::::t=r-~

.--------c~~~

R5486

Figure 12-40. Battery Capacity Indicator Wiring Diagram Without Lift Lockout

•
INDEX PART NO.
NO. NO. PART NAME REQD.
1 021718 CONNECTOR 2
2 021206 TERMINAL 1
3 - NOT USED
4 021207 TERMINAL 1
5 010617-Q1 INDICATOR, 12V BAT CAPACITY 1

• PDM0495 12-61

https://forklift-manuals.jimdofree.com
 41
BATIERY
CAPACITY
INDICATOR
2
_...- TO
' LIFT
5 ... 44 ~VALVE
I " ' I SWITCH
_
t-----Ot-=-=-~
....... .....
PUMP MOTOR
SOLENOID

•
R5487

Figure 12-41. Battery Capacity Indicator Wiring Diagram With Lift Lockout

INDEX PART NO.

NO. NO. PART NAME REQD.
1 021718 CONNECTOR 3
2 021203 TERMINAL 1
3 021206 TERMINAL 1
4 021207 TERMINAL 1
5 010618-01 INDICATOR, 12V BAT CAPACITY 1

12-62 PDM0495
•
https://forklift-manuals.jimdofree.com
•

TO
TERMINAL
BOARD

• KEYSWITCH

ELEC.PANEL
RESISTOR
R3263

Figure 12-42. Optional Key Switch

INDEX PART NO.

NO. NO. PART NAME REQD.
1 020725 SWITCH KEY 1
2 021203 TERMINAL, RING 2
3 021204 TERMINAL, QUICK 2
DISCONNECT, FEMALE
4 005422 CONNECTION, IN-LINE, 1
INSULATED
5 023014 WIRE AR

• PDM0495 12-63

https://forklift-manuals.jimdofree.com
 NOTES

41

~·

12-64 PDM0495
•
https://forklift-manuals.jimdofree.com
•

https://forklift-manuals.jimdofree.com
- - -------------
 (~

https://forklift-manuals.jimdofree.com