Section

Page

Section

Page

1

DESCRIPTION

1-1

7

TRANSMISSION SERVICING

7-1

1-1

INTRODUCTION

1-1

7-1.

TRANSMISSION REPLACEMENT

7-1

1-2

GENERAL DESCRIPTION

1-1

7-2.

DRIVE WHEEL REPLACEMENT

7-1

1-3

SAFETY FEATURES

1-2

7-3.

LOAD WHEEL REPLACEMENT

7-1

1-4

OPTIONS AND ACCESSORIES

1-2

8

ELEVATION SYSTEM SERVICING

8-1

2

OPERATION

2-1

8-1.

GENERAL

8-1

2-1.

GENERAL

2-1

8-2.

RAM HEAD REMOVAL

8-1

2-2.

OPERATING PRECAUTIONS

2-1

8-3.

YOKE SHEAVE REPLACEMENT (FULL FREE LIFT)

8-2

2-3.

BEFORE OPERATION

2-2

8-4.

LIFT CHAIN ADJUSTMENT

8-2

2-4

INSTRUMENTS AND CONTROLS

2-4

8-4-1-

TELESCOPIC AND NON-TELESCOPIC

8-2

2-4.1.

STEERING ARM AND CONTROL HEAD

2-4

8-4-2.

FULL FREE LIFT

8-3

2-4.2.

;IFT/LOWER CONTROL

2-5

8-5.

LIFT CHAIN INSPECTION

8-3

2-4.3.

BATTERY DICONNECT

2-5

8-6.

LIFT CHAIN REPLACEMENT

8-4

2-4.4.

OPTIONAL FEATURES

2-5

8-6.1.

TELESCOPIC AND NON-TELESCOPIC

8-4

2-5.

OPERATION

2-6

8-6.2.

FULL FREE LIFT

8-4

2-5.1.

FORWARD AND REVERSE TRAVEL AND SPED CONTROL

2-6

8-7.

LIFT CYLINDER REMOVAL

8-4

2-5.2.

STEERING 

2-6

8-7.1.

TELESCOPIC AND NON-TELESCOPIC

8-4

2-5.3.

STOPPING

2-6

8-7.2.

FULL FREE LIFT

8-4

2-5.4.

PARKING

2-7

8-8.

MAST REMOVAL

8-5

2-5.5.

BATTERY CHARGING

2-7

8-9.

LIFT CARRIAGE REPLACEMENT

8-5

2-5.6.

LOAD HANDLING

2-7

9

HYDRAULIC SYSTEM SERVICING

9-1

2-5.7.

MIVING A DISABLED TRUCK

2-7

9-1.

RELIEVING SYSTEM PRESSURE

9-1

3

PLANNED MAINTENANCE

3-1

9-2.

FLOW CONTROL VALVE REPLACMENT

9-1

3-1.

GENERAL

3-1

9-3.

SUMP PUMP FILTER REPLACEMENT

9-1

3-2.

MONTHLY AND QUARTERLY CHECKS

3-1

9-4.

LINE OR FITTING REPLACEMENT

9-4

3-3.

BATTERY CARE

3-1

9-5.

LIFT/LOWER CONTROL VALVE

9-4

3-3.1.

GENERAL

3-1

9-5.1.

ADJUSTMENT

9-4

3-3.2.

BATTERY SERVICING

3-2

9-5.2.

DISASSEMBLY

9-4

3-3.3.

CHARGER OPERATION

3-2

9-5.3.

PUMP MOTOR SWITCH ADJUSTMENT

9-5

3-4.

LUBRICATION

3-2

9-6.

HYDRUALIC PUMP AND MOTOR ASSEMBLY

9-6

4

TROUBLESHOOTING

4-1

9-6.1.

PUMP AND MOTOR ASSEMBLY REMOVAL

9-6

4-1.

GENERAL

4-1

9-6.2.

HYDRAULIC PRESSURE ADJUSTMENT

9-6

5

STEERING ARM AND CONTROL HEAD SERVICING

5-1

9-7.

LIFT CYLINDER REPAIR

9-6

5-1.

GENERAL

5-1

9-7.1.

NON TELESCOPIC AND TELESCOPIC

9-6

5-2.

BELLY-BUTTON SWITCH ADJUSTMENT

5-1

9-7.2.

FULL FREE LIFT

9-8

5-3.

CONTROL HEAD SWITCH REPLACEMENT

5-2

10

ELECTRICAL COMPONENTS

10-1

5-4.

SPEED CONTROL SWITCH RETURN SPRING REPLACEMENT

5-4

10-1.

CONTACTOR SERVICING

10-1

5-5.

STEERING ARM RETURN SPRING ADJUSTMENT

5-4

10-1.1.

2^ND AND 3^RD SPEED CONTACTOR DISASSEMBLY

10-1

5-6.

STEERING ARM RETURN SPRING REPLACMEENT

5-6

10-1.2.

2^ND AND 3^RD SPEED CONTACTOR REASSEMBLY

10-1

5-7.

PIVOT TUBE REPLACEMENT

5-7

10-1.3.

FORWARD-REVERSE CONTACTOR DISASSEMBLY

10-2

5-8.

ELECTRICAL CONTROL CABLE REPLACEMENT

5-8

10-1.4.

FORWARD-REVERSE CONTACTOR REASSEMBLY

10-3

5-9.

STEERING ARM AND PIVOT CAP REPLACEMENT

5-10

10-2.

PUMP MOTORS

10-3

6

BRAKE SERVICING

6-1

10-3.

DRIVE MOTORS

10-3

6-1.

GENERAL 

6-1

10-4.

BATTERY CHARGER

10-3

6-2.

ADJUSTMENT

6-1

10-4.1.

TROUBLESHOOTING 004978 BATTERY CHARGER

10-5

6-2.1.

ADJUSTMENT FOR TRUCK SERIAL NUMBERS 333032 TO 333755

6-2

10-5.

BATTERIES

10-8

6-2.2.

ADJUSTMENT FOR TRUCK SERICAL NUMBERS 333756 AND HIGHER

6-2

10-6.

HIGH SPEED LIMIT SWITCH

10-8

6-3.

REPLACEMENT OF DISC BRAKE PARTS

6-3

11

OPTIONAL EQUIPMENT

11-1

6-3.1.

PARTS REPLACEMENT FOR TRUCK SERIAL NUMBERS 33032 TO 333755

6-3

11-1

KEYSWITCH

11-1

6-3.2.

PARTS REPLACEMENT FOR TRUCK SERIAL NUMBERS 333756 AND HIGHER

6-3

11-2.

HOUR METER

11-1

6-4.

BRAKE LEVER REPLACEMENT (FOR TRUCKS WITH SERIAL NUMBER 333032 TO 333755)

6-5

11-3.

BATTERY CAPACITY INDICATOR

11-1

11-4.

REMOTE CONTROL

11-1

11-5.

REMOTE CONTROL INSTALLATION

11-1

11-5.1.

PUSHBOTTON BOX REMOTE CONTROL

11-1

11-5.2.

CONTROL HEAD LIFT/LOWER

11-1

11-6.

COLD-CONDITIONING

11-1

12

ILLUSTRATED PARTS BREAKDOWN

12-1