DP IBH MANUAL LIFT TRUCKS SERIES 14A, 14P, 14S, 21A, 21P, 21R (IBH1177_14XX-14AXX-14PXX-14SXX-17XX-21XX-21AXX-21PXX-21RXX-51BXX-52AXX)

TABLE OF CONTENTS
SECTION		PAGE	SECTION		PAGE
I	DESCRIPTION		3-3	Preventive Maintenance	3-1
1-1	Introduction	1-1/2-1	3-4	Cleaning	3-1
1-2	Description	1-1/2-1	3-5	Lubrication	3-1
II	OPERATION		3-6	Troubleshooting	3-2
2-1	General	1-1/2-1	3-7	Adjustment and Repair	3-3
2-2	Operating Precautions	1-1/2-1	3-8	Hydraulic Unit Removal and Installation	3-4
2-3	Propelling and Stopping the Lift Truck	1-1/2-1	3-9	Hydraulic Oil Draining and Refilling	3-4
2-4	Turning the Lift Truck	1-1/2-1	3-10	Release Valve	3-5
2-5	Raising the Load	2-2	3-11	Hydraulic Pump and Foot Pedal	3-6
2-6	Lowering the Load	2-2	3-12	Ball Section	3-7
III	MAINTENANCE AND MAINTENANCE PARTS		3-13	Chrome Ram and Inside Cylinder	3-8
3-1	General	3-1	3-14	Lift Chain	3-9
3-2	Part Number Identification	3-1	3-15	Pallet Roller	3-9
			3-16	Adjustable Fork Removal	3-9
			3-17	Brakes	3-11
			3-18	Wheel Removal and Installation	3-12
LIST OF ILLUSTRATIONS
FIGURE		PAGE	FIGURE		PAGE
1-1	Manual Hydraulic Lift Truck Basic Configuration	1-0	3-5	Ball Section Kit	3-7
2-1	Operating Controls	2-2	3-6	Chrome Ram and Packing Material	3-9
3-1	Lubrication and Cleaning	3-2	3-7	Lift Carriage	3-10
3-1	Hydraulic Unit	3-4	3-8	Brake Assembly	3-11
3-3	Release Valve and Linkage	3-6	3-9	Caster Wheel Assembly	3-12
3-4	Pump, Pump Linkage and Foot Pedal	3-7	3-10	Load Wheel	3-13

1-1. INTRODUCTION
This publication describes the IBH Manual Lift Truck Series 14A, 14S, 14P, 21R, 21P, and 21A, manufactured by Big Joe Manufacturing Company Lincolnwood, Illinois 60646. Included are instructions for operation, lubrication, adjustment, and repair. Also included are repair parts list which provide the part number for all maintenance parts.
1-2. DESCRIPTION (Figure 1-1)
The lift truck is equipped with a horizontal handrail with two handle grips for manual propelling and steering. A lever with a handle grip actuates the simple floor brakes. Raising the brake lever to the horizontal position locks the brakes for parking.

Raising and lowering the load is achieved manually through a hydraulic unit. The unit contains a hydraulic oil reservoir, cylinder, ram, release valve, hydraulic pump, and check valve.
Lifting action is achieved by operating a piston-type hydraulic pump with a foot pedal. The pump forces hydraulic oil from the reservoir into the cylinder, raising the hydraulic ram. A chain fitted to the ram head assembly provides lift action as the ram rises. To lower the load, a release pull rod with handle grip opens the release valve, permitting the hydraulic oil to return to the reservoir from the cylinder. As the cylinder oil level decreases, the ram lowers, permitting the load to descend.

2-1. GENERAL.
This section gives detailed operating instructions for the IBH Manual lift trucks. The instructions are divided into the various phases of operations, such as propelling, stopping, turning and operating the lift. Toutine precautions are included to guarantee safe operation.
2-2. OPERATING PRECAUTIONS.
Improper use of the lift truck can cause injury to personel and/or damage to the load. Always observe the following precautions.
1. Leave the load in the down position for overnight storage.
2. Set the brakes before leaving the lift truck, especially when it is loaded.
3. Center the load on the forks (or platform) as far as possible toward the hydraulic unit. NEVER LIFT A LOAD ON THE TIP OF THE FORKS, ON ONE FORK, OR ON THE EDGE OF THE PLATFORM.
4. Do not attempt to lift loads heavier than the rated capacity of the lift truck.
5. Check for obstructions before raising or lowering a load.
6. Lower the load before traveling. If it is necessary to move the load in a raised position to stack pallets, travel cautiously and use extra care in turning.

7. Use only hydraulic oil in the hydraulic system. Never use brake fluid.
2-3. PROPELLING AND STOPPING THE LIFT TRUCK.
1. Check that the load is down.
2. Release the brake.
3. Grasp the two control handle (1, figure 2-1) grips. Push evenly with both hands to move the lift truck forward; pull evenly with both hands to move the lift truck backwards.
4. For normal stopping, slowly pull up on the brake lever (2). For emergency or abrupt stops, sharply pull up on the brake lever.
2-4. TURNING THE LIFT TRUCK.
Front-swivel and rear-swivel lift trucks require different techniques in turning. The following two paragraphs give the correct procedures for turning front swivel and rear swivel lift trucks, respectively.
a. Front Swivel Truck.
A front-swivel truck pivots around the rear wheels and is turned in the following manner:
1. Release the brakes.

2. To turn left, grasp the control handle grips and simultaneously push forward with the right hand and pull backward with the left hand.
3. To turn right, grasp the control handle grips and simultaneously push forward with the left hand and pull backward with the right hand.
b. Rear Swivel Truck.
A rear swivel lift truck pivots around the front wheels and is turned in the following manner:
1. Release the brake.
2. To turn left, grasp the control handle and grips and push the handrail to the right with both hands.
3. To turn right, grasp the control handle grips and push the handrail to the left with both hands.
2-5. RAISING THE LOAD.
Lifting action is achieved by operating the foot pedal (3); thus the rate of ascent depends upon th espeed at which the foot pedal is operated.

CAUTION: Overhead or nearby obstructions may tip or damage the load.
1. Check the space above and near the load for adequate clearance.
2. Position the lift truck for lifting and set the brakes.
3. If the foot pedal is in the vertical (storage) position, lower the foot pedal to normal operating position.
4. Check that the release pull rod lever (4) is down.
5. Pump the foot pedal through its full stroke at an even pace until the load reaches the proper height.
2-6. LOWERING THE LOAD.
The rate of descent depends upon both the amount the release valveis opened and the weight of the load.
1. Slowly open the release valve.
2. When the load is down or reaches the desired height, close the release valve.

3-1. GENERAL.
This section contains information and procedures for preventive and corrective maintenance of the Manual Lift Truck. Preventive maintenance includes cleaning and lubrication. Corrective maintenance includes adjustment, repair, and troubleshooting. Complete information is given in overhauling unit, which comprises the entire hydraulic system of the lift truck.
This section also contains parts lists and illustrations identifying maintenance parts. The callouts on each illustration correspond to the index numbers in the accompanying parts list. Each parts list provides the Big Joe Manufacturing Company part number, the part description, and the quantity of the part required in the assembly.
When identifying each part to be ordered, visually compare the part in the illustration with the actual part needed. To assure proper identification of each part being ordered, include your truck model number, your truck serial number (check nameplate), the part number description, and quantity of the part(s) needed.
3-2. PART NUMBER IDENTIFICATION.
To determine the part number of a replacement part, identify the assembly in which the part is used and locate the illustration of the applicable assembly. Find the index number of the part on the illustration and refer to that index number in the parts list. If the part number is NP, order the next higher assembly. If the part number is VAR, order by part name with truck model number, capacity, lift height, and serial number.
If the part is listed with more than one part number, select the proper part number by comparing the description in the

parts list with the specifications of your truck. Refer to the Data Plate to determine application to your truck.
3-3. PREVENTIVE MAINTENANCE.
3-4. Cleaning.
As frequency of use requires, remove all surface dirt or grease from the:
1. Lifting surface of the forks platform.
2. Friction surface of the brake shoes (1, figure 3-1). Replace these if damaged (paragraph 3-17).
3. Control and propelling bar handle grips.
3-5. Lubrication. (Figure 3-1)
Lubricate the lift truck every six months or 100 hours of use, whichever comes first. Always clean the lift truck before lubrication and wipe away excess grease or oil after lubricating.
1. Apply grease to the fittings on the load wheels (2), caster wheels (3), and the caster swivels (4).
2. Add grease to the fitting at the pulley on the ram head assembly (5).
3. Grease the pallet rollers (6) and apply grease to their fittings.
4. Lightly grease the inside of the mast channels (7).
5. Apply a light coat of oil to the lift chain (8).
6. Oil couplings (9) and other moving parts of the brakes.
7. Oil moving parts of the hydraulic unit (10).
8. Check hydraulic oil level and, if needed, fill hydraulic unit oil reservoir until the oil level is even with or slightly below the filler hole (see paragraph 3-9).

3-6. TROUBLESHOOTING
The simplified design of the lift truck makes diagnosing troubles relatively simple. Table 3-1 is a troubleshooting

guide which lists some possible troubles along with the probable casue and suggested remedy for each.

MALFUNCTION	PROBABLE CAUSE	CORRECTIVE ACTION
TROUBLE WITH LIFTING OR LOWERING
1.Load will not rise.	a. Low hydraulic oil.	a. Add oil as required (para 3-9).
	b. Release valve not closed.	b. Check that release pull rod is in the down position or that release valve is properly adjusted (para 3-10).
	c. Defective hydraulic pump.	c. Check pump and replace or repair as necessary (para 3-11).
	d. Broken or defective foot pedal connections.	d. Check all pivots, springs, and connecting parts. Replace as necessary.
2. Load will not lift to the top.	Hydraulic oil level too low.	Add oil (para 3-9).
3. Load rises but will not lower.	a. Defective release valve.	a. Check and adjust the release valve (para 3-10).
	b. Release pull rod stuck or disconnected.	b. Check pull rod for free movement and all pivot points and connections.
	c. Hydraulic system obstructed.	c. Check obstructions.
4. Load creeps down when in a raised position.	Leak in hydraulic system.	a.Check and adjust release valve (para 3-10).
		b. Look for loose fittings in the hydraulic unit.
		c. Check pump unit for leakage back into reservoir.
5. Load does not rise or move smoothly.	a. Hydraulic oil level too low.	a. Check oil level and add as necessary (para 3-9).
	b. Defective release valve.	b. Check release valve and adjust or replace as necessary (para 3-11).
	c. Defective hydraulic pump unit.	c. Check pump pressure and adjust or replace as necessary (para 3-11).
	d. Defective hydraulic cylinder.	d. Repair or replace as necessary (para 3-13).
	e. Load larger than rated capacity.	e. Reduce load.
	f. Dry pallet rollers or mast channels.	f. Lubricate rollers or inside of mast channels (para 3-5).
	g. Damaged pallet roller.	g. Replace roller (para 3-15).
OTHER TROUBLES
6. Oil sprays or flows from top of the inside cylinder.	Defective packing in inside cylinder.	Overhaul the inside cylinder and install new packing and O-ring (para 3-13).
7. Truck does not stop when brakes are applied.	a. Brakes are loose.	a. Tighten (para 3-17).
	b. Brake shoe pad friction surface is oily.	b. Clean.
	c. Brake shoe pad friction surface is worn.	c. Replace brake shoe plunger assembly.

3-7. ADJUSTMENT AND REPAIR.
The following procedures cover adjustments, replacement procedures, and repair of assemblies. The replacement procedures

include reassembly where the procedures are not obvious from the disassembly procedures. The procedures are independent of each other unless specifically referenced.

3-8. Hydraulic Unit Removal and Installation. (Figure 3-2)
The hydraulic unit is a self-contained hydraulic system. The compact design and easy accessibility of the unit within the lift truck permits fast removal of the unit to a workbench for repair. Periodic maintenance tasks such as lubrication, or routine adjustments such as release valve adjustment can be accomplished without removing the unit from the lift truck. When removal does become necessary, follow the procedure given below.
1. Check that there is no load on the lift truck and that the lift truck is positioned on a solid, level floor.
2. Set the brake and block the wheels to guard against accidental rolling.
3. Raise the forks (or platform) about 12 inches and position strong, 10-inch-high supports (the automotive type is recommended) under the forks. Lower the forks onto the supports and check that the forks are securely positioned before proceeding.
4. Hold the release valve (11) open and press down on the ram head assembly until the ram (3) is in the lowest position.
5. Remove the chain from the ram head assembly. Lay the chain aside.
6. Lift the ram head assembly from the ram.
7. Raise the foot pedal to the vertical, or storage, position and remove the screws (13) securing the hydraulic unit to the lift truck.
8. Pull the base of the unit towards the rear of the truck until the top of the unit slips free of the retaining hole in the lift truck frame.
3-9. Hydraulic Oil Draining and Refilling. (Figure 3-2)
a. Draining
1. Remove the hydraulic unit from the lift truck (see paragraph 3-8).
2. With the hydraulic unit at a workbench, use a vise or other suitable means to secure the unit with the base (8) elevated slightly above the top (6) and with the filler plug (4) turned up.
3. Place a clean container of at least a one-quart capacity beneath the top of the hydraulic unit to catch the draining oil.
4. Hold the release valve (11) open and press down on the chrome ram (3) to make certain that the ram is down as far as possible.
5. Unscrew and remove the filler plug and then loosen the top cap (6) to drain the hydraulic oil.

b. Refilling.
1. Check that the top cap is secure and that the release valve is fully closed.
2. If the filler plug is installed, remove it from the side of the reservoir.

Figure 3-2. Hydraulic Unit

INDEX NO.	PART NO.	PART NAME	NO. REQD.
	039104	Hydraulic unit – 25 in. stroke, 12 oz oil capacity (for models 21P54, 21R54, 21A50, 14S57, 14A54, and 14P54 only)	1
1	900046	Reservoir	1
2	900073	Inside Cylinder	1
3	900074	Chrome Ram	1
	039105	Hydraulic Unit – 32 in. stroke, 16 oz oil capacity (for models 21P68, 21R68, 21A64, 14S71, 14A68, and 14P68 only)	1
1	900048	Reservoir	1
2	900077	Inside Cylinder	1
3	900079	Chrome Ram	1
	039106	Hydraulic Unit – 37 in. stroke, 19 oz oil capacity (for models 21P80, 21R80, 21A76, 14S83, 14A80, and 14P80 only)	1
1	900049	Reservoir	1

Hydraulic Unit (Cont.)

INDEX NO.	PART NO.	PART NAME	NO. REQD.
2	900078	Inside Cylinder	1
3	900080	Chrome Ram	1
4	900052	Filler Plug	1
5	900038	Filler Plug Gasket	1
6	900072	Top Cap (with O-ring)	1
7	900041	O-ring	1
8	900351	Base	1
9	900032	Ball Section (see figure 3-5)	1
10	---	Foot Pedal Pump and Linkage (See figure 3-4)	1
11	---	Release Valve and Linkage (see figure 3-3)	1
12	---	Hydraulic Ram Packing (see figure 3-6)	1
13	063555	Hex Head Cap Screw, 5/16-18 x 1	2
14	077210	Washer, 5/16	2
15	900155	Lever Operated Release Valve and Linkage Kit (see figure 3-3)	1
16	900028	Pump Linkage Kit (see figure 3-4)	1
17	900352	Gasket	1
	900027	Minor Repair Kit, consisting of
	900031	Pump Seal Kit (see figure 3-4)	1
	900035	7/32 in. Ball	2
	900036	5/16 in. Ball	1
	900039	Cotter Pin	4
	900040	Release Valve Packing	1
	900041	O-ring	1
	900042	Valve Ring Gasket	1
	900043	Ball Spring	1
	900044	Leather Washer	1
	900054	Release Valve Packing Nut	1
	900057	Plunger Cup	1
	900058	Grommet	1
	900071	Pal Nut	1
	900026	Major Repair Kit, Consisting of
	900028	Pump Linkage Kit (see figure 3-4)	1
	900030	Release Valve Arm Kit (see figure 3-3)	1
	900032	Ball Section Kit (see figure 3-5)	1
	900033	Release Valve Unit Kit (see figure 3-3)	1
	900034	Ram Plunger Packing Kit (see figure 3-6)	1
	900067	Pump (see figure 3-4)	1

NOTE: It is recommended that the hydraulic unit be filled with Big Joe Hydraulic Jack Oil, part number 055779 (1 qt.).
3. With the unit in an upright position, use a small funnel or other means to add hydraulic oil. Fill until the oil level is even with or slightly below the filler hole.
4. Install and tighten the filler plug. Wipe away any hydraulic oil that may have spilled during filling.
5. Return the lift truck to operating condition.
3-10. Release Valve. (Figure 3-3)
a. Adjustment.
Perform the following procedure to adjust the hydraulic unit release valve.
1. Remove the release return spring (14, figure 3-3).

2. Loosen retaining screw (19) sufficiently to move release valve arm (18).
3. Slide the release valve arm down (clockwise) while holding the release valve arm extension (17) up to obtain 1/8 to ½ inch clearance between base and arm when release valve spindle (20) is tightened firmly with the fingers. If, when performing this operation, a 1/8-inch minimum clearance cannot be obtained, perform steps a through d below.
(a) Remove retaining screw (19) and washer (16).
(b) Remove release valve arm from the hex head of the release valve spindle and, with the spindle tightened firmly with the fingers, index the slotted hole in the release valve arm one notch counterclockwise and reinstall on the spindle head.
© Reinstall screw and washer but do not tighten,
(d) Perform step 3 above.
4. Tighten retaining screw.
5. Reinstall release return spring.
b. Disassembly.
Perform the following procedure when repair of the release valve is necessary.
1. Remove the hydraulic unit from the lift truck and drain the hydraulic oil (paragraphs 3-8 and 3-9).
2. Secure the unit in a vise and remove cotter pin (15); then pull the lower end of the release pull rod (11) free of the release valve arm extension (17).
3. Remove the release return spring (14).
4. Remove retaining screw (19) and washer (16) and pull the release valve arm (18) from the hexagonal head of release valve spindle (20). Detach release valve arm extension (17).
5. Remove the release valve packing nut (21), which also removes pal nut (22) and the release valve spindle. Separate the three parts if replacement is necessary.
6. Turn the unit over and shake out the leather washer (23), release valve packing (24), and steel ball (25). If necessary, use a small screwdriver or similar tool to work the parts out.
c. Assembly.
NOTE: It is recommended that certain parts (indicated in figure 3-3) be replaced each time the equipment is dismantled. These parts are available separately or as part of release Valve Arm Kit, No. 900030.
Reverse the procedure of paragraph b to assemble the release valve and linkage.

Figure 3-3. Release Valve and Linkage

INDEX NO.	PART NO.	PART NAME	NO. REQD.
		Release Valve and Linkage
		The following parts are available individually or as part of Lever Operated Release Valve and Linkage Kit, No. 900155
	900087	Clamp Assy	1
1	NP	U-Bolt	1
2	NP	Clamp Bracket	1
3	NP	Cap Screw	1
4	NP	Lock Washer	2
5	NP	Hex Nut	2
6	900093	Washer	1
7	900090	Hex Nut	2
8	900092	Spacer	1
9	900091	Lock Washer	1
10	900088	Release Pull Rod Lever	1
11	900086	Release Pull Rod	1
12	900059	Washer	1
13	060403†	Cotter Pin	1
		The following parts are available individually or as part of Release Valve Arm Kit, No. 900030*
14	900053	Release Return Spring	1
15	060403†	Cotter Pin	1
16	900059	Washer	2
17	900083	Release Valve Arm Extension	1
18	900082	Release Valve Arm	1

INDEX NO.	PART NO.	PART NAME	NO. REQD.
19	900084	Sems Screw	1
		The following parts are available individually or as part of Release Valve Unit Kit, No. 900033*
20	900085	Release Valve Spindle	1
21	900054†	Release Valve Packing Nut	1
22	900071†	Pal Nut	1
23	900044†	Leather Washer	1
24	900040†	Release Valve Packing	1
25	900035†	7/32 in. Ball	1
†Included in Minor Repair Kit, No. 900027 (see figure 3-2 parts list)
*Included in Major Repair Kit, No. 900026 (see figure 3-2 parts list)
**Should be replaced when equipment is dismantled

3-11. Hydraulic Pump and Foot Pedal. (Figure 3-4)
a. Disassembly
1. Remove the hydraulic unit from the lift truck and drain the hydraulic oil (see paragraphs 3-8 and 3-9).
2. Remove the left and right foot pedal weldments (20, 21) by removing four screws and washers (22, 23).
3. Remove cotter pins (15) securing foot pedal (18) to pump linkages (10); then detach the foot pedal.
4. Remove the cotter pin (14) to remove clevis pin (12), pump linkages and washers (13).
5. Lift off spring retainer (11), pump link spring (16), and pump cover (17).
6. Remove the pump assembly (1) by unscrewing the assembly from the base of the hydraulic unit.
7. Unscrew pump cap (2) and remove pumnp packing (7) from the cap.
8. Remove pump housing (3).
9. Carefully place pump plunger (4) in a vise and remove nut (6).
10. Slip off brass retainer (5), leather washers (8), and O-ring (9).
b. Assembly.
NOTE: It is recommended that certain parts (indicated in figure 3-4) be replaced each time the equipment is dismantled. These parts are available separately or as part of Minor Repair Kit, No. 900027.
Reverse the procedure of paragraph a to assemble the hydraulic pump and foot pedal. Place sealer on the pump threads when installing the pump assembly into the base.

Figure 3-4. Pump, Pump Linkage and Foot Pedal

INDEX NO.	PART NO.	PART NAME	NO. REQD.
	---	Pump, Pump Linkage, and Foot Pedal
1	900067*	Pump (Complete)	1
2	NP	Pump Cap	1
3	NP	Pump Housing	1
4	NP	Pump Plunger	1
5	NP	Brass Retainer	1
6	NP	Nut	1
		The following parts are available as Pump Seal Kit, No. 900031†
		For ½-in. Pumps:
**7	9000359†	Pump Packing	1
**8	9000360†	Backup Washer	2
**9	9000361†	O-ring	1
		For 9/16-in. Pumps:
**7	900068†	Pump Packing	1
**8	900069†	Backup Washer	2
**9	900070†	O-ring	1
	---	Pump Linkage
		The following parts are available as Pump Linkage Kit, No. 900028*
10	900045	Pump Link	2
11	900060	Spring Retainer (for 9/16 in. pumps)	1
	900278	Spring Retainer (for ½ in. pumps)	REF
12	900076	Clevis Pin	1
13	900055	Washer	5
14	900039†	Cotter Pin	1
15	060403†	Cotter Pin	2
16	900062	Pump Link Spring	1
17	900061	Pump Cover	1
	---	Foot Pedal
		The following parts are available as Foot Pedal and Weldment Kit, No. 900029 (see note)

INDEX NO.	PART NO.	PART NAME	NO. REQD.
18	900064	Foot Pedal	1
19	900075	Pedal Pad	1
		The following parts are available as Weldment Kit No. 900283
20	900285	Foot Pedal Weldment (right)	1
21	900286	Foot Pedal Weldment (left)	1
22	900284	Cap Screw	4
23	900287	Lock Washer	4
Note: 900029 also includes 2 each of Items 900039 and 900055
*Included in Major Repair Kit, No. 900026 (see figure 3-2 parts list)
†Included in Minor Repair Kit, No. 900027 (see figure 3-2 parts list)
**Should be replaced when equipment is dismantled

3-12. Ball Section. (Figure 3-5)
a. Disassembly.
1. Remove the hydraulic unit from the lift truck and drain the hydraulic oil (see paragraphs 3-8 and 3-9).
2. Use a wrench to remove valve plug (5).
3. Use a small screwdriver or pointed tool to remove valve ring gasket (4) and the ball spring (3).
4. Tilt the unit over and shake out the 5/16-inch ball (2) and 7/32-inch ball (1). If necessary, tap unit lightly on the workbench to dilodge two balls.

Figure 3-5. Ball Section Kit

INDEX NO.	PART NO.	PART NAME	NO. REQD.
		The following parts are available individually or as Ball Section Kit No. 900032*
1	900035†	7/32-in. Ball	1
2	900036†	5/16-in. Ball	1
3	900043†	Ball Spring	1
**4	900042†	Valve Ring Gasket	1
5	900056	Valve Plug	1
*Included in Major Repair Kit, No. 900026 (see figure 3-2 parts list)
†Included in Minor Repair Kit, No. 900027 (see figure 3-2 parts list)
**Should be replaced when equipment is dismantled

b. Assembly.
NOTE: It is recommended that certain parts (indicated in figure 3-5) be replaced each time the equipment is dismantled. These parts are available separately or as part of Minor Repair Kit, No. 900027.
Reverse the procedure given in paragraph a to assemble the ball section.
3-13. Chrome Ram and Inside Cylindr. (Figure 3-6)
a. Disassembly
1. With the hydraulic unit out of the lift truck and drained of hydraulic oil (see paragraphs 3-8 and 3-9), lay the unit on a workbench and remove the top cap by unscrewing it with a wrench.
NOTE: If the top cap comes off alone, proceed with step 5. If the inner cylinder and chrome ram come free with the top cap, perform steps 2 through 4.
2. Withdraw the combination of top cap, inner cylinder, and chrome ram from the reservoir.
CAUTION: Excessive pressure may damage the inner cylinder.
3. Carefully clamp the inner cylinder in a vise and use a wrench to remove the top cap. Remove the O-ring from inside the top cap.
CAUTION: The highly polished chrome ram may be damaged if dropped or brought into sharp contact with metal objects.
4. CArefully withdraw the chrome ram from the inner cylinder.
NOTE: If steps 2 through 4 were performed, go to step 8.
5. If the top cap comes off alone, remove the O-ring inside the top cap.

CAUTION: The higly polished chrome ram may be damaged if dropped or brought into sharp contact with metal objects.
6. Secure the base of the unit in a vise and carefully remove the chrome ram from the inner cylinder.
NOTE: For (all newer) lift trucks with lever operated release pull rod, it is necessary to loosen the clamp and U-bolt securing the release valve linkage to the reservoir before continuing with the next step.
7. Break the reservoir free of its bond to the base and withdraw it a sufficient distance to permit access to the lower portion of the inner cylinder; then unscrew the inside cylinder from the base. Remove the inner cylinder and the gasket (17, figure 3-2) from the unit.
8. Disassemble the chrome ram by removing plunger cup nut spreader (1, figure 3-6).
9. Remove the grommet (2) and plunger cup (3).
10. Remove the ram limit ring (4) by using a pointed tool or small screwdriver to work the ring from the retaining groove,
b. Assembly
NOTE: It is recommended that certain parts (indicated in figure 3-6) be replaced each time the equipemnt is dismantled. These parts are available separately or as part of Minor Repair Kit, No. 900027.
1. Install the ram limit ring (4) by fitting the ring into the retaining groove on the chrome ram.
2. Install the plunger cup (3) and grommet (2).
3. Install and tighten the plunger cup nut spreader (1).
NOTE: Inner cylinder must be installed with threaded end at bottom of assembly (toward base).
4. Secure the base of the hydraulic unit in a vise and insert the inner cylinder into the reservoir. Hold the bottom of the reservoir a sufficient distance from the base to permit access to the lower end of the inner cylinder, then screw the inner cylinder into the base.
5. Carefully insert the chrome ram into the inner cylinder. Push the ram as far in as possible.
CAUTION: When mating the reservoir and base, the mating surfaces must be sealed tightly.

6. Generously apply gasket cement or adhesive such as Armstrong Industrial Adhesive N-171 to shoulder and side of base (the surface that mates with bottom and side of reservoir.)
NOTE: The adhesive container may have special instructionsfor using the adhesive.
7. Allow adhesive to get tacky and check that none has spread or run below the shoulder.
8. Set replacement gasket and reservoir into base and align properly.
9. Install replacement O-ring in top cap.
10. Grease mating threads of top cap and reservoir.
11. Install and tighten top cap (115 to 120 ft-lbs of torque recommended). Be certain to maintain reservoir alignment while tightening top cap.
NOTE: For (all newer) lift trucks with lever operated release pull rod, it is necessary to tighten the clamp and U-bolt which secures the release valve linkage to the unit.

Figure3-6. Chrome Ram and Packing Material

INDEX NO.	PART NO.	PART NAME	NO. REQD.
	900034*	Ram Plunger Packing Kit	REF
1	900037	Plunger Cap Nut Spreader	1
**2	900058†	Grommet	1
3	900057†	Plunger Cup	1
4	900050	Ram Limit Ring	1
**	900041	Top Cap O-ring (see figure 3-2)	1
*Included in Major Repair Kit, No. 900026 (see figure 3-2 parts list)
†Included in Minor Repair Kit No. 900027 (see figure 3-2)
**Should be replaced when equipment is dismantled

3-14. Lift Chain. (Figure 3-7)
a. Adjustment.
1. With the lift carriage (1) fully lowered, open the release valve and press down on the ram head assembly (8) until the ram is as far down as possible.
2. Loosen the upper nut (18) of the chain adjusting assembly.

3. Use a wrench to tighten the lower nut (17) until there is no appreciable slack in the lift chain.
4. Tighten the upper nut.
b. Removal.
1. With no load on the lift truck, set the brakes and block the wheels to guard against accidental rolling.
2. Raise the lift carriage about 12 inches and position strong, 10-inch high supports (the automotive type is recommended) under the forks. Lower the forks onto the supports and check that the position is secure.
3. Hold the release valve open and press down on the ram head assembly until the lift chain (13) can be slipped free from the ram head pulley (9).
4. Remove the cotter pin (15) and clevis pin (14) securing each end of the chain.
5. Remove the chain.
c. Installation
To install the lift chain, perform the steps of paragraph 3-14b in reverse order. After installation, check the lift chain tension and adjust as necessary according to paragraph a.
3-15. Pallet Roller. (Figure 3-7)
a. Removal.
1. Disconnect the lift chain from the lift carriage.
2. Remove the lift carriage from the lift truck. This is accomplished by using an overhead hoist to lift the carriage free or by laying the lift truck over backward and rolling the lift carriage out of the mast channels.
NOTE: Note the location of the thrust washers so that they can be replaced in the same position.
3. With the lift carriage out of the lift truck, the pallet rollers (6) and thrust washers (7) can be slipped free of the spindles (20).
b. Installation.
Replace a pallet roller by reversing the procedure of paragraph a. New rollers may require refitting of thrust washers. Use appropriate thickness to achieve snug fit of rollers to mast channels with minimum sideplay yet allowing rollers to roll free.
3-16. Adjustable Fork Removal. (Figure 3-7)
1. Remove the retaining ring (5) at the end of the shaft (4) on which the fork to be removed is located.
2. Pull the shaft out from the opposite end until the fork is free.

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	---	Lift Carriage and Associated Parts		6	062308	Pallet Roller	4
1	500035	Lift Carriage (Platform type, for series 14S and 21P)	1	7	053000	Spacer Thrust Washer 3/32”	A/R
	500036	Lift Carriage (Platform type, for Series 14P)	1		053001	Spacer Thrust Washer 1/8”	A/R
	500038	Lift Carriage (Fork Type, for Series 21R)	1		053002	Spacer Thrust Washer 5/32”	A/R
	500037	Lift Carriage (Adjustable fork type for Series 14A and 21A)	1		053003	Spacer Thrust Washer 3/16”	A/R
2	025712	Grease Fitting	4		500034	Ram Head Assy
		For Series 14A only:		8	800096	Ram Head	1
3	500924	Adjustable Fork	2	9	800107	Sheave	1
4	296401	Shaft	1	10	060203	Sheave Pin	1
5	061725	Retaining Ring	2	11	061722	Retaining Pin	2
		For Series 21A only:		12	025712	Grease Fitting	1
3	500055	Adjustable Fork	2	13	VAR	Chain (308200)	A/R
4	240603	Shaft	1	14	060303	Chain Pin	2
5	061719	Retaining Ring	2	15	060403	Cotter Pin	2
				16	052752	Chain Adjusting Lug	1
				17	059445	Hex Nut	1
				18	059545	Jam Nut	1
				19	077215	Lock Washer	1
				20	NP	SPindle	4

3-17. Brakes. (Figure 3-8)
a. Adjustment.
1. Release the brakes.
2. To tighten, turn adjustment rod (12) clockwise to expose more threads at clevis (8).
3. TO loosen, turn adjustment rod counterclockwise.
b. Disassembly.
1. Release the brakes.

2. At the left-hand side of the lift truck, opposite the brake handle, loosen set screw (4) securing the brake arm (3) and handle assembly (1).
3. Pull brake arm free of handle assembly and remove woodruff key (5).
4. Remove cotter pins (10) and clevis pins (9) from both sides of the brake assembly.
5. Unscrew the clevis (8) on each side and lift off two adjustment rods (12).

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	501662	Brake Module Assembly (all models except Series 14P)	1	10	060417	Cotter Pin	2
	501663	Brake Module Assembly (for Series 14P only)	1	11	059433	Hex Nut, 7/16-10 thin	2
1	500030	Brake Handle (all models except Series 14P)	1	12	500032	Brake Rod	2
	500124	Brake Handle (for Series 14P only)	1	13	075005	Upper Spring	2
2	057500	Brake Handle Grip	1	14	075006	Brake Lifter Spring	2
3	050601	Brake Arm	1	15	060448	Cotter Pin	2
4	073474	Set Screw	1	16	500108	Brake Plunger with Molded-On Pad (all models except Series 14S)	2
5	057901	Woodruff Key	1		500477	Brake Plunger with Molded-On Pad (for Series 14S only)	2
6	053110	Brake Spacer Bearing	2	17	063552	Hex Head Cap Screw, 5/16-18 x 5/8	2
7	077054	Clevis Spacer	1	18	059426	Hex Nut, 5/16-18	2
8	056201	Brake Clevis	2	19	077210	Lock Washer, 5/16	6
9	060302	Clevis Pin	2	20	VAR	Main Frame	1
				21	057501	Control Handle Grip	2

6. Lift off upper springs (13) and remove cotter pins (15). This permits the two brake lifter springs (14) to be lifted off.
NOTE: Lift truck must be tilted, raised on blocks or otherwise raised sufficiently to permit slipping brake plungers (16) out at bottom of lift truck.
7. Remove brake plungers.
8. Work brake handle assembly out of lift truck, removing spacers (6) as handle comes free.

Figure 3-9. Caster Wheel Assembly

INDEX NO.	PART NO.	PART NAME	NO. REQD.
	054300	3-in. Steel Caster and Wheel Assy (for Series 14A and 14P)	2
	054301	3-in. Rubber Caster and Wheel Assy	2
	054304	3-in. Phenolic Caster and Wheel Assy	2
1	054325	Caster	1

3-18. Wheel Removal and Installation. (Figure 3-9 and 3-10)
Before removing a wheel, slightly raise the side of the lift truck to which the wheel is fixed. This is done most quickly by pushing on the upper part of the lift truck frame to tilt the lift truck. Place blocks of sufficient height beneath the chasis to support the truck and allow the wheel to rotate free of the ground. Check that the arrangement is secure before proceeding. Use figure 3-9 or 3-10, as applicable, as a guide for continuing the procedure.

INDEX NO.	PART NO.	PART NAME	NO. REQD.
2	063580	Axle	1
3	059427	Axle Nut	1
4	077515	Lock Washer	2
5	078206	3-in. Steel Wheel and Bearing Assy	1
5	078207	3-in. Rubber Wheel and Bearing Assy	1
5	078211	3-in. Phenolic Wheel and Bearing Assy	1
	054400	4-in. Steel Caster and Wheel Assy (for Series 21A, 21P, and 21R)	2
	054401	4-in. Rubber Caster and Wheel Assy	2
	054402	4-in. Phenolic Caster and Wheel Assy	2
	054406	4-in. Polyurethane Caster and Wheel Assy	2
1	054425	Caster	1
2	050698	Axle	1
3	059438	Axle Nut	1
5	078400	4-in. Steel Wheel and Bearing Assy	1
5	078401	4-in. Rubber Wheel and Bearing Assy	1
5	078404	4-in. Phenolic Wheel and Bearing	1
5	078408	4-in. Polyurethane Wheel and Bearing Assy	1
6	025712	Grease Fitting	1
7	077058	Thrust Washer	2
	054600	6-in. Steel Caster and Wheel Assy (for Series 14S)	2
	054601	6-in. Rubber Caster and Wheel Assy	2
	054603	6-in. Phenolic Caster and Wheel Assy	2
	054623	6-in. Polyurethane Caster and Wheel Assy	2
1	054602	Caster	1
2	050698	Axle	1
3	059438	Axle Nut	1
5	078600	6-in. Steel Wheel and Bearing Assy	1
5	078601	6-in. Rubber Wheel and Bearing Assy	1
5	078652	6-in. Phenolic Wheel and Bearing Assy	1
5	078654	6-in. Polyurethane Wheel and Bearing Assy	1
6	025712	Grease Fitting	1
7	077058	Thrust Washer	2
8	059426	Hex Nut	8
9	077210	Lock Washer	8

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
1	078250	3-in. Steel Load Wheel and Bearing Assy (for Series 21A, 21P, and 21R)	2	1	079105	10-in. Rubber Load Wheel and Bearing Assy (for Series 14A, 14P, and 14S)	2
1	078252	3-in. Rubber Load Wheel and Bearing Assy	2	2	240601	29-in. Axle (for Series 14A and 14S)	1
1	078253	3-in. Phenolic Load Wheel and Bearing Assy	2	2	240603	25-1/4-in. Axle (for Series 14P)	1
1	078251	3-in. Polyurethane Load Wheel and Bearing Assy	2	3	061719	Retaining Ring	2
1	078450	4-in. Steel Load Wheel and Bearing Assy (for Series 21A, 21P, and 21R)	2	4	077010	Thrust Washer	6
1	078401	4-in. Rubber Load Wheel and Bearing Assy	2	1	079151	10-in. Phenolic Load Wheel and Bearing Assy (For Series 14A, 14P, and 14S)	2
1	078404	4-in. Phenolic Load Wheel and Bearing Assy	2	2	240620	28-in. Axle (for Series 14A, and 14S)	1
1	078408	4-in. Polyurethane Load Wheel and Bearing Assy For 3-in. and 4-in. Load Wheels:	2	2	240621	24-in. Axle (for Series 14P)	1
2	294501	Axle	2	3	061719	Retaining Ring	2
3	061719	Retaining Ring	4	4	077010	Thrust Washer	6
4	077010	Thrust Washer	4

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DP IBH MANUAL LIFT TRUCKS SERIES 14A, 14P, 14S, 21A, 21P, 21R (IBH1177_14XX-14AXX-14PXX-14SXX-17XX-21XX-21AXX-21PXX-21RXX-51BXX-52AXX)

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