CLARK FORKLIFT SPM 639 CTW SERVICE MANUALS

Service and Parts Manual SPM 639

CTW

SERIAL NUMBER ALWAYS GIVE TRUCK SERIAL NUMBER WHEN ORDERING PARTS

CaRlrZ

Material Handling Company

TABLE OF CONTENTS

DESCRIPTION

PAGE 1 2 3 3 4 4 4 6 7 10 10 12 12 12 1 14 15 16 17 18 19 20 21

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Safety information Table of Contents Preventative Maintenance Electrical System Arrival Inspection Pre-Operation Instructions Operating Instructions Brake Adjustment Procedure for Complete Assembly of Blue Giant Gear Box Battery Maintenance Safety Precaution Equalizing Charge Watering Cleaning Gear Box Assembly Diagram Gear Box Assembly Parts List Drive Unit Assembly Diagram Drive Unit Assembly Parts List Steering Handle Assembly Contactors Contactor Panel Assembly - 2 Speed Contactor Panel Assembly - 3 Speed Traction Motor

MPORTANT: READ AND UNDERSTAND THE CONTENTS OF THIS MANUAL BEFORE OPERATING EQUIPMENT SAFETY INFORMATION DO NOT OPERATE THIS TRUCK UNLESS YOU HAVE BEEN TRAINED AND AUTHORIZED TO DO SO. 1

DO NOT OPERATE THIS TRUCK UNTIL YOU HAVE CHECKED ITS CONDITION. GIVE SPECIAL ATTENTION TO TIRES, BATTERY, CONTROLS, LIFTING SYSTEMS INCLUDING SWITCHES, BRAKES, STEERING MECHANISM, GUARDS AND SAFETY DEVICES.

1

REPORT THE NEED FOR TRUCK REPAIRS TO YOUR SUPERVISOR IMMEDIATELY AND DO NOT OPERATE TRUCK UNTIL REPAIRS ARE MADE. NEGLECT MAY CAUSE A MINOR REPAIR TO BECOME A MAJOR SERVICE PROBLEM AND CAUSE THE TRUCK TO BECOME UNSAFE. DO NOT EXCEED THE RATED CAPAICTY

OF THE VEHICLE AS MARKED ON THE NAMEPLATE.

DO NOT LIFT WITH THE FORK TIPS OR ONE FORK ONLY, IF EQUIPPED. UNITS EQUIPPED WITH FORKS ARE DESIGNED FOR EVENLY CENTERED LOADS WITH FORKS COMPLETELY SUPPORTING THE LOAD. OFF CENTERING OF LOADS CAN RESULT IN A DANGEROUS OPERATING CONDITION AND MAY CAUSE DAMAGE OR INJURY. ALWAYS LOOK IN DIRECTION OF TRAVEL. USE CAUTION WHEN LOAD INTERFERES WITH VISIBILITY. EXTREME CAUTION MUST BE USED WHEN HANDLING OR TRANSPORTING LOOSELY STACKED/PACKAGED LOADS. START, STOP, CHANGE DIRECTION, TRAVEL AND BRAKE SMOOTHLY. SLOW DOWN FOR TURNS ON RAMPS AND ON UNEVEN OR SLIPPERY SURFACES THAT COULD CAUSE TRUCK TO SLIDE OR TIP. BE AWARE THAT THE TRUCK BEHAVES DIFFERENTLY WITHOUT A LOAD THAN WITH A LOAD. 1

KNOW AND UNDERSTAND GRADEABILITY CAPABILITIES OF THIS VEHICLE. MAXIMUM RECOMMENDED GRADEABILITYU UNDER LOAD NOT THE EXCEED 5%. STRADDLE TYPE EQUIPMENT IS DESIGNED FOR LEVER SURFACE ONLY. DO NOT LEAVE TRUCK UNATTENDED ON RAMP

1

OBSERVIE APPLICABLE TRAFFICE REGULATIONS. YIELD RIGHT OF WAY TO PEDESTRIANS. SLOW DOWN AND SOUND HORN AT ALL AISLE INTERSECTIONS AND WHERE VISION IS OBSTRUCTED.

b

DO NOT RIDE ON THIS EQUIPMENT UNLESS IT HAS BEEN EQUIPPED AND DESIGNED FOR SUCH USE.

B

DO NOT ALLOW PERSONNEL TO STAND UNDER THE FORKS, IF EQUIPPED (LOADED OR UNLOADED) WHEN FORKS ARE IN THE RAISED POSITION.

.

BEFORE YOU LEAVE THE TRUCK, FULLY LOWER LIFTING EQUIPPED, AND APPLY PARKING BRAKE, IF EQUIPPED.

.

DO NOT USE FORWARD MAST TILT, IF EQUIPPED WITH THE LOAD ELEVATED UNLESS THE LOAD IS DIRECTLY OVER OTHER SUPPORT.

.

WHEN TRAVELLING WITH OR WITHOUT A LOAD, FORKS SHOULD BE IN LOWER MOST POSITION AND TILTED BACK IF APPLICABLE

.

FOR STRADDLE TRUCKS, STRADDLE DISTANCE MUST BE EQUALLY SPACED IN REGLATION TO TRUCKCHASSIS. STRADDLE INSIDE DIMENSION MUST BE SET AT A MINIUM OF 25% OF MAXIMUM LIFTING HEIGHT. STRADDLE LEGS ADJUSTMENT SHOULD BE DONE BY AUTHORIZED BLUE GIANT REPRESENTATIVE.

MECHANISM, SHUT OFF POWER AND KEYSWITCH lF

REMEMBER: A SAFE OPERATOR IS A SMART OPERATOR d

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NOT A CONTROLLED DOCUMENT ,_..

Par’ira 4

PREVENTIVE MAINTENANCE spotting trouble before it happens can prevent costly down-time and extensive repairs and make it possible for service and repairs to be performed when the unit is not required for regular operations. nspection intervals outlined are for normal conditions. More frequent inspections are necessary for adverse renditions such as: rough floor conditions, temperature extremes, several operators, dusty atmosphere, etc.

NSPECTION INTERVALS:

DAILY:

QUARTERLY:

CAUTbN:

Operating Controls (SAFETY) Battery Electrical System Hydraulic System Drive Unit and Mechanical Parts

DISCONNECT THE BATTERY BEFORE ATTEMPTING INSPECTION OR SERVICE

ELECTRICAL SYSTEM he traction motor is 12 or 24 volt series wound. Speed and direction are controlled by contactors. ‘wo direction contactors obtain direction reversal by reversing the motor field connections. Current flow through le armature is always in the same direction. ‘he high speed contactor bypasses the low speed and second speed (if equipped) resistors when energized, ,pplying the full battery voltage to the traction motor. In low speed, current passes through both resistors and in ‘econd speed current passes through one resistor giving the traction motor less than full battery voltage. is the travel controls are rotated (forward or reverse) it actuates a direction micro switch first which energizes the lirection contactor. This establishes direction and low speed. Further rotation actuates the second speed micro ;witch (if equipped) and maximum rotations energizes the high speed switch. Micro switches are adjustable to obtain this sequence.

When the steering handle is in the fully raised or fully lowered position, a micro switch is opened, cutting off power o the direction and speed controls.

3LECTRICAL SYSTEM MAINTENANCE:

,

b Battery should be clean and in good condition.

B All wires and cables should be in good condition and firmly attached to their terminals. l

Compressed air should be used to blow away dirt and dust from all motors, contactors and switches.

l Contact tips should be inspected. Darkening and pitting is normal and replacement should be made when the contact material is burnt away or will be burnt away before the next regular maintenance inspection.

The drive and pump motor brushes should be inspected and replaced when worn to approximately one half of their original length. Spring tension lessens as brushes wear, possibly causing severe burning to the armature commutator. If the commutator has been damaged it must be turned down and undercut before the new shes are installed.

D”“o Q

ARRIVAL INSPECTION This equipment was thoroughly inspected and tested prior to leaving the factory. Before placing the equipment in service it should be thoroughly checked for damage or loss occuring in transit. If any such damage or loss is evident, a claim must be made against the carrier. Refer to Damage in Transit information endosed with the packing slip.

PRE-OPERATION INSTRUCTIONS Remove any packing material and check for visible damage.

0

Open the drive unit cover and check the wiring harness and hydraulic hoses for damage or loose connections.

Imove the breather and check that the oil reservoir is filled to approximately one inch from the top (forks must be in Ilowered position). l

Re

Open the battery compartment and check that all’connections are tight. Check that the battery has not been .maged and is fully charged. Refer to Battery and Charger Instructions.

Refer to the operating instructions and check that the truck operates satisfactorily.

Complete the Warranty Validation form included in this manual and return it to Blue Giant.

OPERATING INSTRUCTIONS T ravel Controls: D#ire&on and speed are selected by rotating the travel control located on the steering handle. For low speed rotate tt re travel control approximately 3/l 6” in forward or reverse as required, an additional l/4” travel for second speed (i f applicable) and maximum rotation for high speed.

C :AUTION: DO NOT USE TRACTION MOTOR FOR BRAKING TRAVEL

SAFETY REVERSXNSG

iorn: 3rclusive feature locates horn pushbutton on each side of the steering handle allowing instantaneous ‘Inger trip use without travel interruption.

See Figure 1 A. Safety Reversing Button:: Located at the top of the steering handle. When truck is moving in the forward direction and the safety reversing button is depressed by an obstruction or trapped operator the vehicle instantly reverses direction, in high speed and the horn will energize.: See Figure 1 A. &id NOTE: DO NOT USE SAFETY REVER&NG BUTI-ON FOR NORMAL TRAVEL ’ Page 4

FIGURE

1A

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Lift and Lower Controls: Push buttons are conveniently located on both sides of the front of the steering handle for left or right hand operation.

CAUTION: DO NOT EXCEED THE RATED CAPACITY OF THE TRUCK AS MARKED ON THE NAMEPLATE. DO NOT LIFT WITH FORK TIPS OR ONE FORK ONLY.

Brake: The brake is applied when the control handle is in the fully raised or fully lowered position. Power to the control circuit is cut off whenever the control handle is in the fully raised or fully lowered position.

CAUTION: .THE BRAKE IS CAPABLE OF HOLDING THE VEHICLE WITH RATEb LOAD ON ANY GRADE ‘WHICH IT CAN NEGOTIATE BUT IS NOT DESIGNED TO STOP A LOADED VEHICLE ON A STEEP GRADE.

BRAKE ADJUSTMENTS 3AKE ADJUSTMENTS PROCEDURE

NOTE: USE IN CONJUNCTION WITH PAGES l- 7 FOR LOCATION OF ITEM NUMBERS

Unplug battery Raise drive wheel off the floor and block the truck securely

TEERING HANDLE UP BRAKE ADJUSTMENT rith the drive wheel off the floor and the steering handle in the fully “UP” position, attempt to turn either the motor Irocket or gear box sprocket by hand. If sprocket can be turned by hand, adjustment is required. Proceed as Illows: AUTION: Do not over adjust brake. The tension on relief springs (Item 59) located on the brake actuator ssembly (Item 54) has been factory set. With steering handle in the raised or lowered positions there must be a ap of not more than 1132” between the bottom of the brake actuator assembly and relief spring lock nuts (Item 52) I protect the internal brake parts of the gear box.

Secure steering handle to drive position.

Heat up position pivot arm (Item 46) to break locktite seal and loosen set screw. DO NOT OVER HEAT. Move pivot arm upward l/32” and tighten set screw. Raise steering handle to the fully raised position, and ttempt to turn either the motor or gear box sprocket by hand. If sprocket can be turned by hand repeat adjustment rocedure until braking is achieved. Secure steering handle to drive position, remove set screw to apply locktite :71 adhesive sealant to the set screw and tighten firmly.

STEERING HANDLE DOWN BRAKE ADJUSTMENT (NOT FOR STAND-ON RIDERS) Secure steering handle to drive position.

Heat the sleeve of down position actuating arm (Item 47) to break locktite seal and loosen set screw.

IO NOT OVER HEAT. 1 Move actuator downward 1132” and tighten set screw. Lower steering handle to the fully lowered position and ittempt to turn either the motor or gear box sprocket by hand. If sprocket can be turned by hand, repeat adjustment procedure until braking is achieved. Secure steering handle to drive position, remove set screw to apply locktite 271 adhesive sealant to the set screw and tighten firmly IF BRAKING CAN NOT BE ACHIEVED AFTER THIS PROCEDURE, BRAKE DISCS MUST BE REPLACED.

BRAKE ACTUATOR ASSEMBLY ADJUSTMENT This adjustment to be done only if actuator is loose or has been removed.

CAUTION: Do not over adjust brake. The tension on relief springs (Item 59) located on the brake actuator assembly (Item 54) has been factory set. With steering handle in the fully raised or lowered positionsthere must bl a gap of not more than 118” between the bottom of brake actuator assembly and relief spring lock nuts (Item 52) tc protect the internal brake parts of the gear box.

Secure steering handle to drive position and remove spring (Item 62) from spring hook (Item 63).

Heat the sleeve of brake actuator assembly (Item 54) to break locktite seal and loosen set screws.

DO NOT OVER HEAT. l Turn the long end of the gear box brake shaft clockwise as far as possible. This is the brake “ON” position of tl gear box brake shaft. Clamp a vise grip onto the short end of the gear box brake shaft. Vise grip should be clamped horizontally pointing towards the tip of the truck forks. DO NOT OVER HEAT. l Hold the vise grip to prevent the gear box shaft from turning counterclockwise and move brake actuator assembly up or down until the long portion of the brake actuator assembly is horizontal. Ensure that bolts (Item 6 are cert&d to the up and down actuator,:

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PROCEDURE FOR COMPLETE ASSEMBLY OF BLUE GIANT GEAR BOX NOTE: USE THIS PROCEDURE IN CONJUNCTION WITH GEAR BOX ILLUSTRATION ON PAGE 2-5.

STEP 1 STEP 2

STEP 3

1 Press Bearing Cup (Item 17 - 016-573) into Main Housing (Item 1 -110-667) Press Bearing Cup (Item 43 - 016562) and seal (Item 26 - 036-093) into Main Cover (item 2 - 110-666) Install Brake Sleeve (Item 13 - 11 O-695) into Main Cover.

Note: One slot of sleeve must be square with top of main cover. Spray locquick Primer T and apply medium strength locktite retaining compound 75) STEP 4

Install Cone Bearing (Item 16 - 016574) Shaft (Item 7 - 11 O-693)

and Key (Item 35 - 021-l 02) onto the Output

STEP 5

Assemble Intermediate Gear Assembly in the order of: 1. Intermediate Gear (Item 4 - 11 O-690).

2. Shaft Key l/4” x 51164” (Item 36 - 021-l 03).

3. Intermediate Gear (Item 5 - 11 O-691).

4. Intermediate Shaft Spacer (Item 6 - 11 o-602).

5. Bearing (item 20 - 016-576) 2 required.

Do not install Upper Bearing (Item 20 - 016-576) into Main Housing Input Bore

STEP 6

Assemble Input Shaft Assembly in the order of: 1. Input Pinion (Item 3 - 110-669).

2. Input Pinion Lock Plate (Item 12 - 11 O-443) Use Locktite #609.

3. Bearing (Item 19 - 016-575).

4. Inner Brake Disc (Item 27 - 023-527) Bronze.

5. Brake Separator Rings (Item 29 - 023-526).

6. Outer Brake Disc (Item 26 - 023-526) Steel.

7. Repeat Items 4, 5 & 6 (6 brake discs, 6 brake separator rings and 7 inner brake discs).

6. Brake Thrust Collar (Item 14 - 11 O-696.)

iTEP 7

1 install Output Shaft (Item 7 - 11 O-893) into Main Housing(ltem 1 - 11 O-887)

;TEP 8

1 Install Seal (Item 25 - 036-092) into Main Housing

STEP 9

1 Install Key (Item 34 - 021-l 01) into Output Shaft (Item 7 - 11 O-893)

STEP 10

1 Install Bearing (Item 20 - 018576) into Main Housing Input Bore

STEP 11

I Install Brake Shaft (Item 9 - 11 O-603) into Main Housing(l1 O-887)

STEP 12

Install Brake Levers (Item 10 - 11 O-604) into Brake Shaft (Item 9 - 11 o-603).

NOTE: Use Locquick Primer T and medium strength Locktite Compound 75 on threads of brake levers before installing into brake shaft

STEP 13

Install Retaining Rings (Item 30 - 013-087) into Brake Shaft (Item 9 - 11 o-603).

NOTE: Centre Brake Levers as close as possible over Input Bearing. Use Shim Washers Item 45 - 012-271) as required between Main Housing and Retaining Rings.

STEP 14

Turn Brake Levers up to allow installation of Intermediate Gear (Item 5 - 11 O-891).

STEP 15

I Install Intermediate Gear (Item 5 - 11 O-891) then turn the Brake Levers down.

STEP 16

Install Output Gear (Item 6 - 11 O-892) into Output Shaft (Item 7 - 11 O-893).

STEP 17

Install Lock Washer (Item 23 - 018-578) and Nut (Item 21 - 018-577). Tighten Nut securely lining up one tooth of Washer with a slot in the Nut. Bend tooth up.

STEP 18

1 Install Dowel Pins (Item 33 - 021-l 05) into Main Housing.

STEP 19

) Install Input Shaft into Main Housing

STEP 20

I Install Snap Ring (Item 15 - 11 O-897) into Brake Sleeve (Item 13 - 11 O-895).

STEP 21

I Install Intermediate Gear Bearing (Item 20 - 108-576) into Main Cover.

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STEP 22

STEP 23 STEP 24

Apply Locktite Gasket Eiminator 515 Sealant on Main Housing machined surface to seal the seam.

I Assemble Main Cover into Main Housing.

Install Spring Washers (Item 41 - 012-270) and Capscrews (Item 31 - 01 O-l 02) and lock.

STEP 25

I Install Cone Bearings (Item 44 - 018-583) into the Output Shaft (Item 7 - 11 O-893).

STEP 26

I Install Primary Nut (Item 46 - 11 l-625) and tighten securely.

, STEP 27

Page 8

I Install Lo&washer (Item 24 - 018-580). Check that one tooth lines up with slot in Primary Nut. _

STEP 28

Install Secondary Nut (Item 47 - 11 l-826). Tighten nut securely, lining up one tooth of washer with a Secondary Nut slot.

STEP 29

Send one tooth of Lockwasher (Item 24) down and one tooth up into slots of Primary and Secondary Nuts.

STEP 30

Apply Locktite Gasket Eliminator 515 Sealant on the Main Cover machined surface around Output Shaft hole.

STEP 31

1 Install Output Shaft Cover (Item 11 - 11 o-605).

STEP 32

1 Install Spring Lockwasher (Item 40 - 012-268) and Capscrew(ltem 32 - 01 O-051) and tighten.

STEP 33

Install Plugs (Item 38 - 021-090) on the top and bottom of Main Housing.

NOTE: Plugs must not be higher than, Main Housing surface at top of Housing.

STEP 34

Fill with oil; use Gulf Harmony #68. Fill until oil is level with filler hole. Install Filler Piug (Item 38 - 021-090) and tighten.

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BATTERY MAINTENANCE lattery life and performance are greatly dependant on the way in which the battery is used and maintained.

5atter-y manufacturer’s instructions supplied with the battery should be posted at the battery charging station.

Jpon Receipt of Battery: 1 1 1 1 1

Examine for physical damage or loss of acid.

Report actual or suspected damage to carrier.

Give battery an equalizing charge.

Check electrolyte level IMMEDIATELY after charging and add water if needed.

When adding water, the electrolyte height should be as specified on page l-1 2 (Watering).

torage of Batteries: /hen your battery will be out of service for 3 or more months.

Give an equalizing charge.

Store in a cool and dry location.

Check specific gravity of several cells at regular intervals and when it falls to 1.240 or below, give another equalizing charge.

SAFETY PRECAUTION . . Explosion can result from the gases produced by a battery.

a) Do not smoke, use an open flame or create arcs or sparks in the vicinity of a battery.

Only charge a battery in a well ventilated area with the cover of battery or compartment raised for m:?.~r%ui 1) rentilation.

2. Severe burns can be caused by the sulfuric acid contained in the batteries covered by these instructions: Do not get acid in eyes, on skin or clothing. In case of contact, flush immediately and thoroughly with clea water.

In handling sulfuric acid, wear a face shield, plastic or rubber apron and gloves. Avoid spilling acid. b) Bicarbonate of soda solution (one pound to a gallon of water) will neutralize any acid accidentally spilled 0 4 clothing or material. Apply the solution until bubbling stops, then rinse with clean water.

When diluting concentrated acid, always add acid to water. Pour slowly and stir constantly, to avoid 4 excessive heat or violent chemical reaction.

al

3. The battery is electrically live at all times: Keep the top of the battery clean and dry to prevent shorts and corrosion.

Do not lay metallic objects on the battery; insulate all tools used in working on the battery to prevent shor b) circuits. Also remove all jewelery before working on the battery.

Be careful when working on battery plugs.

4

4

1. When lifting the battery, observe the following procedures.

Unless completely insulated liing means are available, temporarily cover the top of all cells with an nsulating material (plywood, thick rubber, etc.) to reduce the risk of a short circuit from the chain or hooks.

Use a lifting device whose two hooks are electrically insulated from each other to prevent short circuits.

4 Follow the instructions on handling loads covered on OSHA 1910.179(n).

3

3)

5. Keep the vent plugs firmly in place at all times except when adding water or taking hydrometer and temperature readings.

6 . Only personnel who have been trained in battery installation, charging and maintenance should be allowed to work on the battery.

INSTALLATION OF BATTERIES .

When lifting the battery, use an insulated device which exerts a vertical pull on the lifting tabs. .

During transit and storage a battery may have lost some of its charge. Give it an equalizing charge before Ming the battery in service.

OPERATION .

Full charge gravity of a new battery will be specified on nameplate. Full charge gravity will be affected by ?mperature, acid level and age. If acid is lost from overfilling, full charge gravity and capacity will be lowered.

1. .

A battery should not be discharged more than 80% of its rated capacity during a regular work period. This allows for reserve capacity for emergencies and provides protection against aging and gradual loss of capacity. jravity reading will drop as battery is discharged or worked. When fully discharged, it will range from 1 .I 51; ‘ 4 ‘! 3 lepending on type of battery. Repeated discharge below limiting gravity will shoeen battery life.

1.

Never add acid or special solutions to cells.

1.

Keep plugs and receptacles in good condition.

CHARGING 1.

2.

Batteries should be charged by automatic equipment that properly regulates the charging rate and terminate: the charge when complete.

For proper charging, observe that:

a) b) c> *’ +Jd)

Hydrometer reading at end of recharging should indicate specific gravity of acid not less than shown on battery label.

Temperature readings at end of charge should not be more than 25 degrees higher than at start of charge and should not exceed 100 degrees F. Normal water consumption is about 118” drop of acid level per day cycle of charge and discharge.

Loosen the vent caps but do not remove them during charging.

Page 11 .j

EQUALIZING CHARGE hile each charge is intended to bring the battery very close to a fully charged condition, it should be quite oroughly recharged at regular intervals. In typical motive power service, it is usually done weekly, and is known ; an Equalizing Charge.

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1 equalizing charge is an extra three to four hours charge at a low rate. This ensures that alt cells are in fully rarged condition after a normal charge. Regular battery readings should be taken with a hydrometer or volt meter Id a record kept. Readings should never be taken directly after water has been added.

WATERING Use only approved water. That is: 1) distilled water: or 2) de-mineralized water; or 3) local water that has been approved for use in batteries. Never add acid or other foreign material to the battery.

Ideally, water should be added to the battery when it is near the end of charge and gassing. As the electrolyte is at its maximum level during this time, it is certain that the level established by the addition of water will not be exceeded at any other time and overflow of the electrolyte (flooding) will never occur. When watering at the end of charge, sufficient water should be added to bring the level of the electrolyte to within 5” of the bottom of the vent well ring.

It is often inconvenient or impossible to be present at the end of charge to perform watering. In this case, it is recommended that the battery be watered as soon as. possible after the termination of charging, as in this way levels will still be near the maximum and the danger of over-or-under-water is minimized. As a general rule, when watering is done after the end of charge, sufficient water should be added to bring the electrolyte level tc within 1” to 1.25” from the bottom of the vent well ring. The above levels will vary as a function of how long the battery has been charged and are intended only as a guide. Exact water levels should be determined based on individual experience when watering is performed after charging is complete.

Check acid levels daily until a regular interval for adding water is established. In Motive Power Service, the addition of water is usually necessary at weekly intervals, although this time period may be extended based on experience.

A cell filler is an excellent tool for a convenient and accurate method of adding water: however, care must be taken to adjust the cell filler using appropriate spacers such that it will water cells to levels in accordance with items 2 and 3.

CAUTION: Avoid over filling as resultant over flow of electrolyte will cause tray corrosion, ground paths and loss of capacity or working ability.

CLEANING If battery tops become wet and dirty, or if any tray corrosion is visible, give battery a soda wash. Mix a handful of bicarbonate soda (Baking Soda: Arm and Hammer: Cow Brand, etc.) in a bucketful of water. Pour this solution all over top of battery until bubbling stops. (Be sure vent caps are in place).

Then wash the battery down with clean water. ,%A Page 12

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GEAR BOX ASSEMBLY

43)' 'i \-l

GEAR BOX ASSEMBLY ‘EM l-

d2

3 4 5 6 7 8 9 I(0 11 12 1’3 14 15 l16 17 18 19 2 !O 2 !l 2 !2 2 !3 4 !4 2 !5 z‘6 : !7 :!8 :29 \<30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

T1 1 1 1 1 1 1 1 2 1 1 1 1

1 1 1 1 3 1 1 1 1 1 7 6 6 2 6 4 2 1 1 1 4 4 6 2 1 1 ,S REC

1 1

PART NO. 110-881 11 O-888 11 O-889 11 O-890 11 O-891 11 O-892 11 O-893 11 O-602 11 O-603 11 O-604 11 O-605 110-443 11 O-895 11 O-896 11 O-897 110-911 018-573 018-574 018-575 018-576 018577 --~~~~~~~~~~ 01.8-578 018-580 036-092 036-093 023-527 023-526 023-526 013-087 01 o-1 02 01 O-051 021-l 05 021-l 01 021-l 02 021-l 03 -----021-090 ----------012-268 012-270 036-091 018-582 018-583 012-271 111-625 111-626

DESCRIPTION Main Housrng Main Cover Input Pinion intermediate Pinion Intermediate Gear Output Gear Output Shaft Intermediate Shaft Spacer Brake Shaft Brake Operating Levers Output Shaft Cover Input Pinion Lock Plate Brake Sleeve Brake Thrust Collar Input Pinidn Snap Ring Socket Pipe Plug l/8” NPT x 112” Bearing Cup Bearing Cone Bearing Bearing Lock Nut - 1-l 12” - TN09 Lock Washer - TN09 Lock Washer - TN08 Seal - Garlock Seal - Garlock Inner Brake Disc - Bronze Outer Brake Disc - Steel Brake Separator Springs Retaining Rings Socket Capscrew - 318-l 6 x 1-l 12” Socket Capscrew - 114-20 x 314” Dowel Pin Shaft Key - 3/8” x 3” Shaft Key - 318” x 718” Shaft Key - 114” x 51164” Socket Pipe Plug - 318” Spring Lock Washer - 114” Spring Lock Washer - 318 O-Ring Seal Bearing Cup Bearing Cone Spacer Washer Primary Nut Secondary Nut

INOTE: Use 1-l /4 quart of oil. l Gulf Harmony #68 I Esso Terreso #68 ,Shell Covil #68 pr equals Page 1 +d,.

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TRACTION MOTOR OTY

f

1 2 3 4 5 6 7 8 8 9 10 11 12 12 13 14 15 16 16 17 18 19 20 21 22 22 23

2 1 1 1 1 1 1 1 1 1 8 2 1 1 2 2 1 4 1 2 4 2 1 2 1 1 1

‘ART NO.

ESCRIPTION

130-707 130-644 130-620 130-621 130-623 130-624 330-623 330-622 330-625 030-708 030-626 030-627 030-628 030-629 030-709 030-630 030-631 030-632 030-633 030-710 030-634 030-635 030-636 030-637 030-638 030-639 030-711 030-640 030-641

Complete Motor - 12 Volt >ompiete Motor - 24 Volt dotor Clamp Screw Irive End Assembly spring Washer spacer Washer Spring Washer Nasher - Shim 3all Bearing - Drive End Armature - 12 Volt Armature - 24 Volt Ball Bearing - Commutator End Nut Washer Stator - Complete - 12 Volt Stator - Complete - 24 Volt Bushing Screw Brush Plate Assembly (Less Brushes) Brush Set - 12 Volt Brush Set - 24 Volt Bushing Washer Washer Commutator End Assembly Motor Clamp Screw Steel Band Brush Cover - Complete - 12 Volt Steel Band Brush Cover - Complete - 24 Volt Shaft Kev

CTW DECALS ITEM NUMBER 1 2 3 4 5 6

PART NUMBER 2348904 2377063 1747748 2777635 108-646 814-060

%%A Page 22

CITY 1 1 1 1 1 2

DESCRIPTION Decal - #” Clark Logo Decal - Warning Decal - Battery Warning Decal - No Riding Decal - Do Not Charge Here Decal - Forward & Reverse

‘he following addendum is for units equipped with the “Electronic Speed Control”. Any parts or information not isted herein, please refer to standard parts lists previously listed in this manual

INDEX . . . . . . . l . q

Travel Control Direction & Speed Control Brakes Variable Speed Control Panel Assembly Direction Contactors - 275 Amps I 400 Amps Steering Handle Assembly Trouble Shooting Guide Operation & Maintenance Speed Control Potentiometer Test Procedure Speed Control Potentiometer Adjustment

‘RAVEL CONTROL: The Direction and Speed Controls are located on the steering handle and can be Operated by thumb or palm. This unit is equipped with Electronic Speed Controls and has variable speed which is regulated by rotating the controls.

IIRECTION

AND SPEED CONTROL:

The traction motor is 12 or 24 volt serious wound. Speed is regulated by electronic speed control and direction is controlled by contactors.

Two direction contactors obtain direction reversal by reversing the motor field connections. Current flow through the armature is also controlled by the same direction wntactors but is always in the same direction.

BRAKES: Blue Giant recommends plug braking be used on all products equipped with the electronic speed controller to assure smooth controlled stops and changes in direction. Use the service brake only for emergency stops and as a parking brake.

VARIABLE SPEED CONTROL PANEL ASSEMBLY i-EM

CITY

PART NO.

m

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784-560 784-559 784-513 784-512 026-479 026-474 026-481 026-480 026-l 79 026-l 46 030-066 025-669 025-858 025-840 025-842 784-591 784-590 784-589

1 1 la la 2 3 4 5 5 5a 5a 6 7 8

1 1 1 2 *

1

1 1 1 1 2 3 1

DESCRIPTION Complete Contactor Panel Assembly - 275 Amp - 12 Volt *.

Complete Contactor Panel Assembly - 275 Amp - 24 Volt Complete Contactor Panel Assembly - 400 Amp - 12 Volt Complete Contactor Panel Assembly - 400 Amp - 2 4 Volt Controller - 275 Amp - 275 Amp - 12 Volt Controller - 275 Amp - 275 Amp - 24 Volt Controller - 275 Amp - 400 Amp - 12 Volt Controller - 275 Amp - 400 Amp - 24 Volt Fuse Holder Fuse - 6 Amp Terminal Strip Contactor - 275 Amp - 12 Volt Contactor - 275 Amp - 24 Volt Contactor - 400 Amp - 12 Volt Contactor’- 400 Amp - 24 Volt Cable Assembly Cable Assembly Cable Assembly

6 1 j/TO CURTIS M-

.

4

DIRECTION CONTACTOR - 275 AMPS ‘EM

CITY

PART NO.

m 025-869 B 025-858 1 1 025-862 2 1 025-863 3 1 025-864 4 1 025-865 5 2 025-894 025-895 6a 2 025-896 6b 2 7a 2 025-897 7b 2 025-898 iommon to 12 & 24 Volt s

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DESCRIPITON Reversing Contactor Set - 12 Volt Reversing Contactor Set - 24Volt Stationary Contact Moveable Contact Single Normally Closed Fixed Contact Double Normally Closed Fixed Contact End Assembly Coil - 12 Volt Coil - 24 Volt Contactor - 12 Volt (part of 025-869) Contactor - 24 Volt (part of 025-858)

DIRECTION CONTACTOR - 400 AMPS Y--

ITEM e 025-869 w 025-858 *1 025-862 l 2 1 025-863 l 3 1 025-864 l 4 1 025-865 5 2 025-894 6a 2 025-895 6 b 2 025-896 2 025-897 J.7a 7b 2 1 025-898 l Common t o 1 2 & 24 Volt m

1

’

DESCRIPITON

Reversing Contactor Set - 12 Volt Reversing Contactor Set - 24Volt Stationary Contact Moveable Contact Single Normally Closed Fixed Contact Double Normally Closed Fixed Contact End Assembly Coil - 12 Volt Coil - 24 Volt Contactor - 12 Volt (part of 025-869) ’ J Contactor - 24 Volt (part of 025-858)

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STEERING HANDLE ASSEMBLIES

k STAKMATE 780-867 b

81-882-l

7a1:au

PT-WI mw

029-521 826-2690

025-560

TROUBLE SHOOTING GUIDE - ELECTRONIC SPEED CONTROLLER his Trouble Shooting Guide is for the Electronic Speed Controller only (travel faults only) or other faults not listed herein refer to Trouble Shooting guide listed previously in this manual.

AULT: NO TRAVEL -NO RUN PROBABLE CAUSE: Battery disconnected.

SOLUTION: Inspect battery connector and battery cables. Repair as required.

PROBABLE CAUSE: Battery discharged.

SOLUTION: Recharge battery. See Recharging Instructions in Battery Maintenance Section.

PROBABLE CAUSE: Control fuses blown.

SOLUTION: Replace fuses. If new fuse blow, inspect all electrical wiring for short circuit.

Repair as required.

PROBABLE CAUSE: Loose or poor wire connection.

SOLUTION: Inspect and repair as required. See Wiring Diagram.

1ULT: NO TRAVEL - ONE DIRECTION ONLY PROBABLE CAUSE: Faulty micro switch in direction control assembly.

SOLUTION: Inspect and replace as required. See Steering Handle Assembly.

PROBABLE CAUSE: Loose or poor wire connection.

SOLUTION: Inspect and repair as required. See wiring diagram.

PROBABLE CAUSE: One half of speed control potentiometer in direction control assembly faulty (pot open).

SOLUTION: Test and replace as required. See speed control potentiometer test procedure.

AULT: NO TRAVEL - LIFT/ LOWER PROPERLY PROBABLE CAUSE: Faulty Micro Switch in Direction Control Assembly SOLUTION: Replace fuse. If new fuse blows, inspect all electric wiring for short circuit.

Repair as required.

PROBABLE CAUSE: Direction contact malfunction.

SOLUTION: Inspect and repair as required. See Contactor Assembly.

PROBABLE CAUSE: Dead-Man Limit Switch Malfunction.

SOLUTION: Inspect and repair as required. See Drive Unit Assembly.

PROBABLE CAUSE: Loose or poor wire connection.

SOLUTION: Inspect and repair or replace as required. See Wiring Diagram.

PROBABLE CAUSE: Traction motor brushes worn out.

SOLUTION: Inspect and repair as required. See Traction Motor.

Refer to Electrical System for motor brush maintenance.

PROBABLE CAUSE: Faulty speed control potentiometer in direction control assembly (pot open).

SOLUTION: Test and repair as required. See speed control potentiometer test procedure.

PROBABLE CAUSE: Faulty ekctronic speed control unit.

SOLUTION: Test and replace as required. See electronic speed controller unit.test procedure.

DOUBLE SHOOTING GUIDE - ELECTRONIC SPEED CONTROLLER - Cont’d...

4lJLT:

LURCHING START - ONE DlRECTION ONLY - OPPOSITE DIRECTION REQUIRES EXCESSlVE

ROTATION OF CONTROL SWITCH

PROBABLE CAUSE: Speed control potentiometer in direction control assembly improperly adjusted, SOLUTION: Test and adjust as required. See Speed Control Potentiometer Test Procedure and Adjustment.

2UJLT: LURCHING info FULL SPEED REVERSE WHEN THE STEERING HANDLE IS MOVED INTO THE TRAVEL POSITION PROBABLE CAUSE: Faulty safety reversing button.

SOLUTION: Inspect and repair as required. See Steering Handle Assembly.

PROBABLE CAUSE: Faulty safety reversing switch.

SOLUTION: Inspect and repair as required..

PROBABLE CAUSE: Faulty control relay (stuck closed).

SOLUTION: Inspect and repair as required.. See Wiring Diagram.

:ALJLT: LURCHING FULL SPEED START IN BOTH DIRECTIONS PROBABLE CAUSE: Wire number 8, white and wire #9, orange/black are shorted to each’other somewhere in the system.

SOLUTION: Inspect and repair as required. See Wiring Diagram.

PROBABLE CAUSE: Speed control potentiometer is shorted out internally.

SOLUTION: Test and replace as required. See Control Potentiometer Test Procedure

=AULT:

SAFETY REVERSING BUTTON INOPERATIVE

PROBABLE CAUSE: Faulty safety reversing button.

SOLUTION: Inspect and repair as required. See Steering Handle Assembly.

PROBABLE CAUSE: Faulty safety reversing switch.

SOLUTION: Inspect and repair as required. See Steering Handle Assembly. . PROBABLE CAUSE: Loose or poor wire connection.

SOLUTION: Inspect and repair as required. See Wiring Diagram.

.

PROBABLE CAUSE: Faulty control relay (stuck open).

SOLUTION: Inspect and repair as required. See Wiring Diagram.

.

PROBABLE CAUSE: Faulty diode in drive unit terminal block assembly SOLUTION: Inspect and repair as required. See Wiring Diagram.

OPERATION and MAINTENANCE URRENT MULTIPLICATION ne of the most intriguing aspects of the Electronic Speed Controller is the fact that during acceleration, or reduced >eed operation, it allows more current to flow into the motor than flows out of the battery. This is possible because le controller acts like a D.C. transformer, ie: it takes in high voltage (the full battery voltage) and low current, and As out low voltage and high current. Thus for these conditions the battery only has to supply a fraction of the Jr-rent required by a resistor type controller in which the battery current and motor current are always equal. The :sult is a dramatic improvement in the vehicle’s efficiency, this shows up as more driving range per battery charge.

WENT LIMITING .nother feature of Electronic speed Controllers is their ability to limit the motor current to a preset maximum. This urrent limit feature protects the controller from damage which might result in the current were limited only by the lotor demand. The current limit feature is also very important to the rest of the system because it reduces the tresses placed on the motor, drive train and batteries. Motor and battery efficiency and service life are both nproved by eliminating high current surges during vehicle acceleration. This also saves wear and tear on vehicle *ansmissions and drive trains and floor surfaces.

JNDERVOLTAGE CUTBACK ‘he controller must have a means of preventing operating at very low battery voltages. This is because the control :ircuitry requires some minimum voltage of function properly. For this reason, the controller is designed so that its butput is gradually reduced if the battery voltage falls below a certain level: for the standard 24 - 36 volt models this rappens at 16 volts. By reducing the output to the motor, the battery voltage can recover and an equilibrium is established in which the battery is allowed to supply as much current as it can without falling below 16 volts.

I-ERMINAL

PROTECTION

t-he design of these transistorized motor controllers has placed a great deal of emphasis on thermal management lnd in normal operation they barely get warm. If however, the controller is undersized for its application or otherwise overloaded, overheating may occur. If the internal temperature of the controller exceeds 165OF, the :urrent limit will be reduced to approximately one half of its rated value. This will generally allow vehicle operation St a reduced performance level, t allow maneuvering out of the way and stopping in a good place. When the :ontroller cools down, full current limit and performance will automatically return.

PLUG BRAKING In most applications of these controllers, the vehicle motor will be of the series field type. If a series field motor is reversed while the vehicle is moving, a form of electrical braking called plug braking may be used to slow the vehicle down. When the motor is reversed, the armature acts as a generator. Current from the armature flows through a “plug diode” built into the controller. The controller regulates the current in the motor field winding to give an appropriate level of plug braking torque. The vehicle brakes smoothly to a stop, then automatically accelerates in the other direction. The plugging current is factory set, but can be field adjusted to suit special applications.

‘ERATIONAL NOTES While in normal operation the controller is silent, during plug braking with series motors a small whistle may be noticed. This is normal and indicates that plugging is occurring. It will cease when the vehicle reverses.

-.. .I:’ -: *

If a vehicle is rolling back down a steep ramp in reverse, and the pedal is depressed demanding forward drive, the controller will first attempt to plug the vehicle to stop. If the plugging current set point is insufficient to stop the vehicle (ramp too steep), it will continue to be braked but will roll down the ramp. If the mechanical brakes are applied, and the vehicle is stopped, the full drive current will be available and the vehicle will proceed up the ramp.

The controllers have features designed to protect against the damage caused by low batteries. The power to the motor is cut back when the battery voltage goes below approximately 16 volts (for 24 - 36 volt controllers).

The loss of power felt when the batteries become this far discharged is normal. Similarly, the controllers are protected against damage from overheating by reducing the power to the motor if the internal temperature exceeds 165OF. In typical applications of these.units, overheating will very rarely be a problems.

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MAINTENANCE .--> ,

:ONTROLLER he electronic speed controllers (series motor), being a sealed, solid state unit, requires almost no maintenance. I, ; recommended however, that the following items be checked occasionally as required.

CAUTION:

BEFORE DOING ANY WORK ON THE VEHICLE, REMOVE POWER BY DISCONNECTING BATTERY

3 Make sure that the electrical connections to the controllers (as well as those to the motors, batteries, etc.) are tight. When checking the controller bus bar connections for tightness, be sure to use the double-wrench technique to avoid putting stress on the bus bars which could crack the seals around them. ))

Remove from the terminal area any corrosion or accumulations of dirt, acids, grease, oil, etc. It is especially important that the controller terminal face be free of these substances since their presence may lead to electrical leakage and cause faulty operation. The controller may be washed off with a hose or wiped clean with a moist rag. In either case, power must be removed from this cleaning and not reapplied until the wntroller terminal area is thoroughly dry.

- . . ..

SPEED CONTROL POTENTIOMETER TEST PROCEDURE -0 determine that the speed pot is operating properly, follow the steps outlined below. Use the wiring eference.

diagram

as a

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3) I)

Disconnect battery.

Remove the drive unit cover to expose the drive unit terminal strip.

Remove the white wire from the left side of terminal block #8.

Remove the orange I black wire from the left side of terminal block #9.

Using any common multimeter that has the ability to measure resistance, attach the orange I black wire to meter positive and the white wire to meter negative. Select the RX1 0 OHMS range if available.

I With the speed control switch at rest in the truck stopped position, the meter should read over 5000 OHMS resistance.

I Slowly rotate the speed control switch in the forward direction. The meter reading should immediately change 6to approximately 4000 OHMS resistance and then gradually reduce to below 200 OHMS resistance at the maximum speed forward position. ) Return the speed control switch to the truck stopped position and repeat instructions #7 in the reverse direction. ) If the meter readings are as indicated above, the speed pot is adjusted correctly and is operating properly.

0) If the meter reading is as indicated in one direction but remains at over 500 OHMS resistance in the other direction, the speed pot has one side open and must be replaced.

1) If the meter reading is over 5000 OHMS resistance at all times, the speed pot is fully open and must be replaced.

2) If the meter reading is below 200 OHMS resistance at all times, the speed pot is fully shorted and must b: replaced.

3) If the speed pot requires adjustment, see below and follow instructions, 2, 3, 4, 5, 17, 18, 19, and 20 .

SPEED CONTROL POTENTIOMETER ADJUSTMENT Vhen installing a new speed pot, follow the instructions outlined below. The speed pot must be adjusted properly #o that it can act as a throttle to control the travel speed of the truck. Use the wiring diagram as a reference. ) Disconnect battery. ! ) Remove the left and right handle grips. !) Remove the safety reversing switch. Leave wires attached.

C) Remove the left and right direction rotators j) Remove the speed and direction control switch assembly. Leave the wires attached. j) Remove the drive unit cover to expose the drive unit terminal strip.

7) Remove the white wire from the left side of terminal block #8.

3) Remove the orange I black wire from the left side of terminal block #9.

3) Using any common multimeter that has the ability to read resistance, attach the orange I black wire to meter positive and the white wire to meter negative. Select the RX1 0 OMHS range if available.

10) To install a new speed pot, cut off the orange and white wires approximately 2” away from the pot.

11) Loosen fully the pot retaining nut and remove the pot complete with drive gear.

12) The drive gear is a press fit. Note the location of the gear on the pot shaft and remove. Press the gear onto the new pot shaft, allowing turning clearance between the gear and the pot shaft bushing.

13) Trim the orange and white wires to an appropriate length and join to the truck wires with permanent wire connectors. Orange to orange and white to white.

14) Slowly rotate the pot gear and shaft until the meter reading is over 5000 OHMS. This is the open pot to truck stopped position.

15) Without rotating the pot shaft, install the pot into the speed and direction control switch, ensuring that the drive gears are fully engaged and fully tighten the pot retaining nut.

16) The pot shaft will have rotated slightly during this installation and must be adjusted.

I’

17) Temporarily install one direction rotator. Slowly rotate the direction switch from truck stopped to full speed forward, back to truck stopped, to full speed reverse and back to truck stopped, observing the meter throughout. If the meter does not read over 5000 OHMS when at rest in the truck stopped position, hold the rotator to prevent movement of the pot drive gear, insert a screw driver in the slotted end of the pot shaft and rotate the pot shaft slightly inside the drive gear. This is a delicate adjustment and patience is required.

Repeat above, observing the meter at all times, until the meter reading is over 5000 OHMS resistance when the rotator is at rest in the truck stopped position.

18) Remove the temporarily installed rotator and reassemble the components into the steering handle. Observe the contact with any moving parts, and use removable locktite on the rotator set screws.

19) Replace the white wire into terminal block #8 and the orange I black wire into terminal block #9.

20) Replace the drive unit cover, connect the battery and test drive the truck.

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DRIVE UNIT ASSEMBLY

56

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3

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40

DRIVE UNIT ASSEMBLY EM

!TY

‘ART NO.

IESCRIPTION

‘EM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 -7 8 88

11 g-500 ‘86-377 15-456 ‘86-376 11 l-509 15-457 118-074 )17-001 11 o-000 112-202 112-208 I 15-458 I 15-459 11 l-573 33-212 23-015 34-355 30-707 30-644 18-037 15-460 11502 12-200 12-211 1 O-006 ‘89-687 135-204 112-210 I1 l-506

irease Fitting fandle Bracket Assy Yevis Pin Jpper Brake Actuator Arm iex Nut 518” .ower Brake Actuating Arm Yanged Bushing spring Zapscrew -ock Washer 114” -Iat Washer 3116” Zover Plate Zapscrew- Modified Jam Nut ive Belt procket

41 42 3

!l 22 23 34 25 26 27 28 29

2 1 1 1 4 1 2 1 3 4 2 1 1 2 1 1 1 1 1 1 1 4 2 4 4 2 1 1 1 1

!9

1

30 31 32 33 34 35 36 37 38 39 40

4 4 1 1 1 1 1 1 1 1 1

i9 !O

11 O-01 2 112-201 118-039 121-l 04 11 O-067 912-222 313-010 103-819 D18-563 01 l-563 111-653

,ey raction Motor - 12 V raction Motor - 24 V ‘aper Bushing iapscrew - Modified lex Nut 5116-j 8 .ock Washer 5/l 6” :lat Washer 5116” apscrew 5116-l 8 x 1’ lotor Mounting Plate Assy Zable Clamp ‘lat Washer lex Nut 114-20 2ontactor Panel Assy - 2 Speed Zontactor Panel Assy - 3 Speed Capscrew 318-l 6x 314” Split Lock Washer 318” Taper Bushing

5 7 8 9 0 1 2 13 14 i5 i7 i8 i9 j0 Y 52 53 54 54 55 6 57 58 69 70 71 72 73

n-Y 1 1 2 2 2 1 1 1 1 3 1 5 5 1 2 2 1 2 2 2 1 1 1 1 2 2 4 4 1 1 1 1 2

ART NO.

:SCRIPTION

‘87-250 ‘90-351 11 O-01 2 114-001 112-201 Ill-603 790-291 790-292 313-019 312-211 Ill-608 11 l-552 112-201 ‘85-916 I1 4-003 I1 l-003 125-535 117-031 11 o-1 05 113-019 109-l 07 Ill-607 132-300 332-302 31 O-077 312-252 01 O-044 012-220 01 o-1 01 012-232 013-005 023-011 012-252

,ive Tire sar Box Assembly lpscrew 3/8-l 6 x 314” et Screw l/4-20 ock Washer 318” ip Position Pivot Arm Iown Position Pivot Arm #pring Retainer Assembly :otter Pin ‘lat Washer Ip Position Brake Pivoting Arm mock Nut 318” ,ock Washer 318” Brake Actuator Assembly Set Screw 5/l 6-18 x 5116” Machine Screw 6132 x 1” Micro Switch Spring Capscrew 3118-l 6 x 2-112” Cotter Pin Srping Spring Hook Horn - 12 Volt Horn - 24 Volt Capscrew 318-l 6 x l-1 14” Flat Washer Capscrew l/2-1 3 x 2” Lock Washer 112” Capscrew 518-l 1 x 3” Internal Lock Washer 518” Spring Pin 5132” x 3 Speed 1 Sprocket Flat Washer 318”

t

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Key Caspcrew 3/4-l 0 x l-1 12 Washer Spring Pin Retaining Plate Bearing Cone Lock Nut Washer

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Page

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EM-

CR!- E 9RT Na,

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18a 19 20 20 21 22 23 24 24 k

1 6 2 2 2 2 2 4 5 1 1 1 1 1 2 4 4 1 1 5 2 3 1 4.

4 3 4 1

7‘85947 a 125-501 a I1 l-1 06 C113-005 7 ‘85-945 C I1 4-002 7 ‘85-946 C Ill -104 ( 114-055 i 785-957 1 I 16-280 (117-039 785-956 ;125-631 116-108 Ill-104 X2-226 325-633 025-632 01 l-550 105-559 025-055 105-959 01 o-1 37 012-225 025-626 025-626

STEERING HANDLE ASSEMBLY RIPTION

Steering Handle Weldment Push Button Button Head Screw - 318-l 6 x 314” Spring Pin Travel Control Set Screw - 114-20 x 318” Handle Button Head Screw - 114-20 x 112” Carriage Bolt - 114-20 x 2-l/2” Safety Reversing Cap Back Cover Plate Spring Steering Handle Top Plate Safety Reversing Push Button Direction Legend Plate Button Head Screw - 114-20 x l/2 Internal Tooth Lock Washer - 114” Speed Direction Controller - 2 Speed Speed Direction Controller - 3 Speed Acorn Nut Horn Legend Plate Snap-In Plug Horn Legend Plate Hex Head Screw 1 O-32 x 318” Lockwasher #lO Direction Switches - 2 Speed Direction Switches - 3 Speed Control Cable - State Model & Serial Number

HIGH SPEED CONTACTOR TEM

DIRECTION CONTACTOR

PART NO.

DESCRIPTION

025-839

Complete - 12Volt Complete - 24 Volt Stationary Moveable

025-841 025852 025-853

TEM

Contactor

-

025-840

Contactor

-

025-842

Contact Kit Contact Kit

1 2 3 4

Page 18

JTY PART NO.

1 1 1

025-854 025-855 025856 1

025-857

DESCRIPTION Complete Contactor - 12Volt Complete Contactor - 24 Volt Stationary Contact Kit Moveable Contact Kit Single Normally Closed Fixed Contact Double Normally Closed Fixed Contact

CONTACTOR PANEL ASSEMBLY 2 SPEED

:M Q T Y

PART NO.

* s 1 1 2 2 3 3 4 5 6 7 8

765-634 Complete Panel Assembly - 12 Volt Complete Panel Assembly - 24 Volt 785-632 025840 Direction Contactor - 12 Volt Direction Contactor - 24 Volt 025-842 025-839 High Speed Contactor - 12 Volt High Speed Contactor - 24 Volt 025-841 11 O-655 Resistor - 12 Volt 11 O-022 Resistor - 24 Volt 030-066 Terminal Block 1 0 8 - 9 6 6 - Terminal Block Mounting Strip 787-730 Battery Cable 10” 032-l 01 Battery Cable 6” 032-l 07 Battery Cable 7-l 12”

1 1 1 1 1 1 1 1 1 2 1

DESCRIPTION

CONTACTOR PANEL ASSEMBLY 3 SPEED

QTY

PART NO. 784-633 784-631 025-840 025-842 025-839 025-841 115-282 110-214, 11 O-655 11 O-022 030-066 108-966 787-730

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1 1 2 2 3 3 4 4 5 6

1 1 2 2 1 1 1 1 6 1

H

DESCRIPTION Complete Panel Assembly - 12 Volt Complete Panel Assembly - 24 Volt Direction Contactor - 12 Volt - See Page 2-l 0 Direction Contactor - 24 Volt - See Page 2-l 0 High Speed Contactor - 12 Volt - See Page 2-l 0 High Speed Contactor - 24 Volt - See Page 2-l 0 Resistor - 12 Volt Resistor - 24 Volt Resistor - 12 Volt Resistor - 24 Volt Terminal Block Terminal Block Mounting Strip Battery Cable 10” Batterv Cable 6n

BATTERY tiOStTlVE h

Page 2ti

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