SSC Series. STOCK SELECTOR, COUNTERBALANCED LIFT TRUCK Serial Number to Operation Maintenance Repair Parts List

Transcription

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2 SSC Series STOCK SELECTOR, COUNTERBALANCED LIFT TRUCK Serial Number to Operation Maintenance Repair Parts List Big Joe Manufacturing Company Des Plaines, IL MANUAL Rev D 10/19/2006

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4 TABLE OF CONTENTS Section Page Section Page 1 DESCRIPTION INTRODUCTION GENERAL DESCRIPTION WEIGHT SAFETY FEATURES OPTIONS SAFETY SYMBOLS OPERATION GENERAL OPERATING PRECAUTIONS BEFORE OPERATION INSTRUMENTS AND CONTROLS OPERATION DRIVING AND STOPPING PROCEDURES BRAKING OPERATING LIFT FORK LOADING PARKING EMERGENCY POWER DISCONNECT PALLET CLAMP MOVING A DISABLED TRUCK PLANNED MAINTENANCE GENERAL PERIODIC CHECKS BATTERY CARE GENERAL BATTERY SERVICING LUBRICATION HYDRAULIC SYSTEM CAPACITY LIFT CHAIN MAINTENANCE THROTTLE CONTROL LUBRICATION TROUBLESHOOTING GENERAL RESISTOR THEORY OF OPERATION ELECTRICAL SYSTEM SCR THEORY OF OPERATION ELECTRICAL SYSTEM CONTROL FEATURES CHECKING SCR COMPONENTS MAIN SCR CONTROL CARD CAPACITOR 1C CAPACITORS F, R, 1A AND P POTENTIOMETER IN ACCELERATOR COIL DRIVER MODULE HOURMETER MODE SCR S (1REC, 2REC, 5REC) RECTIFIERS (3REC, 4REC) THERMAL PROTECTOR (TP) FILTER BLOCK (23FIL, ETC) X CHOKE AND REACTOR T3-T STEERING SYSTEM MAINTENANCE GENERAL STEERING CABLE TENSION STEERING SHEAVE REPAIR SHEAVE ASSEMBILES ALIGNING DIRECTION INDICATOR STEERING CABLE REPLACEMENT PRELIMINARY PREPARATION REPLACING LOWER STEERING CABLE REPLACING UPPER SHORT STEERING CABLE REPLACING LONG STEERING CABLE ATTACHING SOCKET ASSEMBLIES TO WIRE ROPE CONCLUDING STEPS BRAKE SERVICING BRAKE PEDAL SWITCH ADJUSTMENT BRAKE CABLE REPLACEMENT BRAKE ASSEMBLY REPLACEMENT DISC BRAKE PAD REPLACEMENT DISC BRAKE ADJUSTMENT TRANSMISSION, DRIVE WHEEL, AND LOAD WHEEL SERVICING DRIVE WHEEL REPLACEMENT TRANSMISSION REPAIR LOAD WHEEL REPLACEMENT ELEVATION SYSTEM SERVICING GENERAL LIFT CHAIN ADJUTSTMENT LIFT CHAIN WEAR INSPECTION LIFT CHAIN REPLACEMENT RAM HEAD REPLACEMENT LIFT CYLINDER REPLACEMENT LIFT CARIAGE REMOVAL LIFT CARIAGE DISASEMBLY HYDRAULIC SYSTEM SERVICING GERNERAL SUMP FILTER REPLACEMENT HANDUP VALVE REPLACEMENT ACCUMULATOR SERVICING AND RECHARGING (24 VOLT SCR TRUCKS ONLY) GENERAL PRECHARGE ADJUSTMENT HYDRAULIC PRESSURE ADJUSTMENT VOLT RESISTOR TRUCKS VOLT SCR TRUCKS THROTTLE VALVE ADJUSTMENT THROTTLE VALVE REPLACEMENT THROTTLE VALVE ACTUATOR REPAIR i

5 TABLE OF CONTENTS - Continued Section Page Section Page 9-9. FLOW REGULATOR VALVE REPLACEMENT (24 VOLT SCR TRUCK - TWO SPEED OPTION) FLOW REGULATOR VALVE REPLACEMENT HYDRAULIC PUMP AND MOTOR ASSEMBLY LIFT CYLINDER REPAIR TRUCKS SERIAL NUMBER TO TRUCKS SERIAL NUMBER TO , , TO AND TO TRUCKS SERIAL NUMBER TO , & , TO , TO ELECTRICAL COMPONENTS HIGH SPEED LIMIT SWITCH OPERATIONAL CHECK HIGH SPEED LIMIT SWITCH ADJUSTMENT (SCR TRUCKS) HIGH SPEED LIMIT SWITCH ADJUSTMENT (RESISTOR TRUCKS) HIGH SPEED LIMIT SWITCH REPLACEMENT (SCR TRUCKS) CONTRACTOR PANEL (RESISTOR TRUCKS) CONTRACTOR SERVICING (RESISTOR TRUCKS) SINGLE POLE CONTACTOR DISASSEMBLY SINGLE POLE CONTACTOR REASSEMBLY DOUBLE POLE CONTACTOR DISASSEMBLY DOUBLE POLE CONTACTOR REASSEMBLY SCR PANEL (SCR TRUCKS) MAIN SCR CONTROL CARD SCR S (1REC, 2REC, 5REC) CAPACITOR REC, 23REC, 25REC REACTOR/CHOKE SCR CONTROL CARD ADJUSTMENT SCR CONTROL CARD ADJUSTMENT INSPECTION CONTACTOR PANEL (SCR TRUCKS) F/R CONTACTOR A AND P CONTACTOR CONTROL UNIT REPAIR RESISTOR CONTROL SCR CONTROL SPEED CONTROL SWITCH MAINTENANCE (RESISTOR TRUCKS) SPEED CONTROL SWITCH MAINTENANCE (SCR TRUCKS) GENERAL SWITCHETTE ADJUSTMENT POTENTIOMETER REPLACEMENT ADJUSTMENT EMERGENCY POWER DISCONNECT CHASSIS MOUNTED ELECTRICAL COMPONENTS ELECTRICAL CABLE MAINTENANCE ELECTRICAL CABLE TENSION ADJUSTMENT REPLACEMENT OF ELECTRICAL CABLE PUMP MOTOR DRIVE MOTOR MOTOR REMOVAL MOTOR REPAIR OPPTIONAL EQUIPMENT FLASHING RED LIGHT FLOOD LAMPS SIDE GUIDE ROLLERS STEEL ROLLER REPLACEMENT POLYURETHANE ROLLER REPLACEMENT BATTERY SDISCHARGE INDICATOR OPTIONAL SAFETY HARNES PALLET CLAMP SLIP ON PLATFORM ILLUSTRATED PARTS BREAKDOWN ii

6 LIST OF FIGURES Figure Page Figure Page A SUPPORTING CLAMP NAME PLATE LOAD CENTER OF GRAVITY STOCK SELECTOR, MODEL SSC SAMPLE OF OPERATOR CHECK LIST OPERATOR S CONTROLS - 24 VOLT SCR TRUCKS OPERATOR S CONTROLS - 12 VOLT RESISTOR TRUCKS STEERING CONTROLS THROTTLE CONTROL LUBRICATION DIAGRAM BATTERY CURRENT MOTOR CURRENT OSCILLATOR FREQUENCY CURVE COIL DRIVE MODULE TEST CIRCUIT SCR TEST CIRCUIT VOLT RESISTOR ELECTRICAL SCHEMATIC VOLT RESISTOR ELECTRICAL SCHEMATIC EV-100 SCHEMATIC DIAGRAM (SHEET 1) EV-100 WIRING DIAGRAM (SHEET 1) STEERING CABLES STEERING WHEEL STEERING CABLES DISC BRAKE TRANSMISSION TORQUE WRENCH DIAGRAM PINION ASSEMBLY LOCATION OF SHIMS LOAD WHEEL LIFT CARRIAGE ASSEMBLY INNER MAST AND RAM HEAD INNER MAST AND RAM HEAD HYDRAULIC SCHEMATIC DIAGRAM, 12 VOLT RESISTOR TRUCKS HYDRAULIC SCHEMATIC DIAGRAM, 24 VOLT SCR TRUCKS (SINGLE SPEED) HYDRAULIC SCHEMATIC DIAGRAM, 24 VOLT SCR TRUCKS (TWO SPEED OPTION) HYDRAULIC SYSTEM, 12 VOLT RESISTOR TRUCKS HYDRAULIC SYSTEM, 24 VOLT SCR TRUCKS (SINGLE SPEED) HYDRAULIC SYSTEM, 24 VOLT SCR TRUCKS (TWO SPEED OPTION) THROTTLE CONTROL THROTTLE VALVE ASSEMBLY PUMP AND MOTOR ASSEMBLY AND 12-VOLT SOLENOID LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER ELECTRICAL CONTROL PANEL - 12V RESISTOR TRUCKS HIGH SPEED LIMIT SWITCH CONTACTOR (SINGLE POLE, SECOND & 3RD SPEED, AND DYNAMIC BRAKE CONTACTOR (DOUBLE POLE, FORWARD - REVERSE MAIN SCR CONTROL CARD TRIMPOTS TEST CIRCUIT CONTACTOR PANEL FORWARD/REVERSE CONTACTOR CONTACTOR, 1A AND PUMP CONTROL CONSOLE, 12V, RESISTOR CONTROL DIRECTIONAL CONTROL SWITCH KIT CONTROL CONSOLE, 12V, RESISTOR CONTROL CONTROL CONSOLE, 24V, SCR CONTROL DIRECTIONAL CONTROL SWITCH SPEED CONTROL SWITCH RESISTANCE CURVE EMERGENCY POWER DISCONNECT CHASSIS MOUNTED ELECTRICAL PARTS - RESISTOR SPEED CONTROL TRUCKS CHASSIS MOUNTED ELECTRICAL PARTS - SCR CONTROL TRUCKS ELECTRICAL CABLE INSTALLATION SIDE GUIDE ROLLER (STEEL) SIDE GUIDE ROLLER (POLYURETHANE) BATTERY DISCHARGE INDICATOR (OPTIONAL) BATTERY DISCHARGE INDICATOR WITHOUT LIFT LOCKOUT SCHEMATIC BATTERY DISCHARGE INDICATOR WITHOUT LIFT LOCKOUT SCHEMATIC OPERATOR SAFETY HARNESS (OPTIONAL) PALLET CLAMP SLIP ON PLATFORM STEERING WHEEL STEERING CABLES PIVOT TUBE ASSEMBLY DISC BRAKE BASE, FRAME, DECALS AND PLATES LOAD WHEEL INNER MAST AND RAM HEAD INNER MAST AND RAM HEAD LIFT CARRIAGE ASSEMBLY HYDRAULIC SYSTEM, 12 VOLT RESISTOR TRUCKS HYDRAULIC SYSTEM, 24 VOLT SCR TRUCKS (SINGLE SPEED) iii

7 LIST OF FIGURES - Continued Figure Page Figure Page HYDRAULIC SYSTEM, 24 VOLT SCR TRUCKS (TWO SPEED OPTION) THROTTLE CONTROL THROTTLE VALVE ASSEMBLY LIFT CYLINDER LIFT CYLINDER LIFT CYLINDER EMERGENCY POWER DISCONNECT CONTROL CONSOLE, 12V, RESISTOR CONTROL DIRECTIONAL CONTROL SWITCH KIT CONTROL CONSOLE, 12V, RESISTOR CONTROL CONTROL CONSOLE, 24V, SCR CONTROL DIRECTIONAL CONTROL SWITCH CHASSIS MOUNTED ELECTRICAL PARTS - RESISTOR SPEED CONTROL TRUCK CHASSIS MOUNTED ELECTRICAL PARTS - SCR TRUCK ELECTRICAL CABLE INSTALLATION V HYDRAULIC PUMP AND MOTOR ASSEMBLY V HYDRAULIC PUMP MOTOR ASSEMBLY V HYDRAULIC PUMP MOTOR ASSEMBLY LIST OF FIGURES - Continued V HYDRAULIC PUMP MOTOR ASSEMBLY DRIVE MOTOR ASSEMBLY DRIVE MOTOR ASSEMBLY DRIVE MOTOR ASSEMBLY ELECTRICAL CONTROL PANEL - 12V RESISTOR TRUCKS SCR PANEL CONTROL PANEL SINGLE POLE CONTACTOR, 2ND SPEED, 3RD SPEED DYNAMIC BRAKE DOUBLE POLE CONTACTOR, FORWARD - REVERSE FORWARD/REVERSE CONTACTOR CONTACTOR, 1A AND PUMP SPEED CONTROL SWITCH FLASHING RED LIGHT FLASHING RED LIGHT FLASHING RED LIGHT FLOOD LAMPS (OPTIONAL) SIDE GUIDE ROLLER (STEEL) SIDE GUIDE ROLLER (POLYURETHANE) BATTERY DISCHARGE INDICATOR (OPTIONAL) OPERATOR SAFETY HARNESS (OPTIONAL) PALLET CLAMP SLIP ON PLATFORM Table Page Table Page 2-1 OPERATOR CHECKS MONTHLY AND QUARTERLY INSPECTION AND SERVICE CHART RECOMMENDED LUBRICANTS LUBRICATION CHART TROUBLESHOOTING CHART SCR TERMINAL FUNCTIONS SCR TROUBLESHOOTING PRELIMINARY TRIMPOT ADJUSTMENT iv

8 PREPARATION FOR USE Upon receipt, visually inspect stock selector and battery charger. If any damage is found, report it to the carrier and to your Big Joe dealer immediately. Remove cardboard banded to forks. Check stock selector and battery charger for scratches and dents. Check to make sure that the lift chains are secure. Inspect for oil leaks and loose wiring connections. Make certain that all assessors and attachments that were ordered are supplied. Provisions have been made to prevent the lift carriage from being moved from a predetermined position during transit. These include the following: 1. A lift carriage locking device (see Figure A) has been installed at the top of the inner mast and the ram head. 2. The positive lead of the lift pump has been disconnected. 3. The lift carriage is banded down to thee straddle legs. To place the lift carriage in operation, perform the following steps: 1. Cut banding which holds the lift carriage to straddles. 2. Connect positive lead to pump motor (inside control cabinet). 3. Raise lift carriage so that inner mast protrudes from the mast section sufficiently to remove yellow shipping clamp (see Figure A). 4. Remove 3/8 inch bolt and yellow shipping clamp from the inner mast and raise head. The lift carriage is now ready for normal operation. Before the stock selector is moved, the battery must be checked, recharged if necessary, and connected. If the stock selector was ordered without a battery, a freshly charged battery of adequate size and proper weight must be installed. Refer to Battery Care in Section III for battery checking instructions. CAUTION: The battery is extremely heavy (Approximately 800 pounds). Do not attempt removal or installation with out power assistance. R3000 Figure A. Supporting Clamp Refer to SECTION 2 for operating instructions and test the following controls: SPEED Control Lever Brake Pedal Braking with Speed Control Lever (SCR vehicles) DYNAMIC BRAKE Pushbutton (Resistor-controlled vehicles) LIFT Control If you do not obtain the proper results, of it improper operation occurs, refer to troubleshooting and repair in SECTION 3. The adjustment and repair procedures are supplement with illustration v

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10 SECTION 1 DESCRIPTION 1-1. INTRODUCTION. This publication describes the SSC series of counterbalanced stock selectors serial number and higher, manufactured by Big Joe Manufacturing Company, Des Planes, Illinois SSC (Figure 1-3) is described in described in detail, with operating instructions, planned maintenance instructions, lubrication procedures, corrective maintenance procedures and a complete parts list with parts location illustrations. Users shall comply with all requirements indicated in applicable OSHA Standards and current edition of A.N.S.I B56.1 Part II. By following these recommendations contained in this manual, you will receive many years of dependable service from your Big Joe Stock Selector. The model number will be found on the name plate (Figure 1-1) along with the serial number, lifting capacity, and load center. Figure 1-3 Shows the serial number locations, if the name plate is missing or illegible. R GENERAL DESCRIPTION. The self-propelled SSC lifts and transports the operator (on the platform portions of the lift carriage) and the payload (on forks or optional payload platform). This permits efficient selection and moving of materials in any area or at any level of the warehouse or storeroom. The design permits one man to perform all operations of selecting the stock, driving the truck, and replacing the stock at the designated place. The battery-powered truck is quiet and without exhaust fumes, allowing operation in closed areas without special provisions for ventilation. The SSC-20 is capable of lifting a 2000-pound payload, and the SSC-30, a 3000-pound payload. The lift carriage rises at a fixed speed but the lowering speed is infinitely variable. When the optional two-speed lift is installed either of two lift speeds can be selected. A manual operator-controlled valve regulates the lowering speed. The reversible DC motor propels the truck in forward or reverse direction throughout the available speed range. The SSC can be driven with the lift carriage raised or lowered; however the speed is restricted when the lift carriage is raised Above 24 inches. A steerable drive wheel makes the truck highly maneuverable. A braking method may be employed by the operator to stop the SSC. SSC lift capacities generally are established for a 24- inch load center. The center of gravity of a capacity load can not exceed the load center specified on the name plate for your truck, as configured at time of delivery from factory. See Figure 1-2 for load center location. Additional lifting equipment such as removable payload platforms and special attachments may alter the load center, and consequently lower the rated lifting capacity of the truck. Figure 1-1 Name Plate R6317 Figure 1-2 Load Center of Gravity

11 Weight CAUTION: Use of a battery weighting less than the weight specified on the truck name plate will affect truck stability. Weight distribution of a counterbalanced truck is critical; therefore the weight of the battery is very important. A battery of less than minimum weight (see name plate) will adversely affect stability, particularly with the lift carriage raised. The battery compartment is fabricated foe thee battery purchased with the truck. A replacement battery must be of proper size and weight for your SSC. The battery spacer must be placed between the battery and the mast when a spacer is required SAFETY FEATURES The SSC is designed with many standard safety features. Some of the convenience options also have safety applications. The following safety features are standard. 1. Dead-man brake to prevent accidental runaway. 2. Automatic high speed limit switch to restrict speed when lift carriage is raised above 24 inches. 3. Key-operated power switch to prevent operation by unauthorized personnel. 4. Handrails and/or safety chains on the platform. 5. Shatterproof plexiglass screen on the front of the platform between operator and moving mast members. 6. Separately fused control circuits and power circuits. 7. Emergency power disconnect system. 8. Horn. 9. Overhead guard. 10. LEFT-RIGHT steer-wheel-position indicator. 11. Hangup feature to stop descending cylinder and mast if lift carriage hangs up on an obstruction OPTIONS Your lift truck may be equipped with any or all of the following options: Hourmeter* Battery discharge indicator Operator safety harness and tether* Lift limit switch and override control Larger capacity batteries with corresponding battery chargers Removable payload platform Flashing red warning light* Headlight Spotlight or floodlight Pallet clamping device* Aisle guide rollers Battery rollers* Two speed lift (24 V SCR trucks only) * Standard item on 24 V SCR trucks. If your Big Joe stock selector has optional equipment or features not covered by this technical manual, check with your Big Joe dealer for applicable supplements or addenda SAFETY SYMBOLS. WARNING: CAUTION: This WARNING sign denotes a hazard. It calls attention to a procedure, practice or the like, which if not correctly performed or adhered to could result in personal injury. This CAUTION sign denotes a hazard. It calls attention to a procedure, practice or the like, which if not correctly performed or adhered to could result in personal injury or damage to the equipment. IMPORTANT:This heading call attention to a procedure, which if not followed, may impede the operation or normal flow of a servicing or repair procedure

12 R6315 Figure 1-3. Stock Selector, Model SSC

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14 SECTION 2 OPERATION 2-1. GENERAL. This section gives detailed operating instructions for counterbalanced stock selector. The various functional systems are first explained to provide a broad understanding of how the truck operates, followed by stepby-step operating procedures. Routine precautions are included to guarantee safe operation OPERATING PRECAUTIONS. WARNING: Improper operation of the stock selector lift truck may result in operator injury, or load and/or lift truck damage. Observe the following precautions when operating the stock selector truck. 1. Do not operate this truck unless you have been trained and authorized to do so, and have read and understand all warnings and instructions in this manual and on the lift truck. 2. Do not operate this truck until the periodic inspection or service has been completed. See Table Overloading will result in damage to the hydraulic system and lift mechanism. Do not exceed the rated lifting capacity. 4. Do not handle unstable or loosely stacked loads. Use special care when handling long, high, or wide loads to avoid tipping, loss of load, or striking bystanders. 5. Center and carry the load as far back toward the lift carriage as possible. Do not pick up loads on tips of the forks. The center-of-gravity of the load must not exceed the load center listed on the name plate. See Figure 1-2 for load center limitations. 6. Pick up loads on both forks. Do not pick up loads on only one fork. 7. Always lower the load when traveling to increase vehicle stability. 8. When stacking pallets in racks, it is necessary to move the load in the raised position. Move slowly and use care when turning at a right angle. 9. Check for obstructions when raising or lowering the lift carriage. 10. Apply the mechanical brake gently except in case of emergency. 11. Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at cross aisles and whenever vision is obstructed

15 2-3. BEFORE OPERATION. Table 2-1 covers important inspection point on SSC lift truck which should be checked prior to operation. Depending on use, some trucks may require additional checks. Figure 2-1 shows a sample format for a Operator Checklist, which can be modified as necessary to fit your operation. WARNING: CAUTION: Period maintenance of this truck by a QUALIFIED TECHNICIAN is required. A QUALIFIED SERVICE TECHNICIAN should check the truck monthly for WARNING: proper lubrication, proper fluid levels, brake maintenance, motor maintenance and other areas specified in SECTION 3. IF the truck is found to be unsafe and in need of repair, or contributes to an unsafe condition, report it immediately to the designated authority. Do not operate it until it has been restored to a safe operating condition. Do not make any unauthorized repairs or adjustments. All service must be performed by a qualified maintenance technician. Table 2-1 Operator Checks ITEM PROCEDURE ITEM PROCEDURE Transmission and hydraulic systems. Forks Check for signs of fluid leakage. Check for cracks and damage; and, that they are properly secured. Wheels Hydraulic controls Check drive wheel for cracks or damage. Move truck to check load wheels for freedom of rotation. Check operation of lift and lower to their maximum positions. Chains, cables and hoses Guards Safety signs Horn Steering Travel controls Check that they are in place, secured correctly, functioning properly and free of binding or damage. Check that safety guards are in place, properly secured and not damaged. Check that warning labels, nameplate, etc., are in good condition and legible. Check that horn sounds when operated. Check for binding or looseness in steering wheel when steering. Check that speed control lever operates in all speed ranges in forward and reverse. Brakes Deadman/Parking brake Battery disconnect Battery charge High speed limit switch Check that brakes release when the brake pedal is depressed. Check that brake pedal raises to upright position when released and brake applies. Check that battery can be disconnected and reconnected. Check for connector damage. Check that battery capacity meter (if equipped) is on F. Allow for enough space to operate truck in high speed. Elevate forks approximately two feet, then test drive truck to check if high speed is cut out

16 R5659 Figure 2-1 Sample of Operator Check List

17 2-4. INSTRUMENTS AND CONTROLS Refer to Figure 2-2 for SCR control trucks, or Figure 2-3 for 12 volt resistor control trucks. Key Switch (1): Used to prevent unauthorized personnel from operating the lift truck. Brake Pedal (2): Used to release the mechanical brake when depressed and engage the brake when released. Steering Wheel Position Indicator (3): Used to indicate the position of forward travel of the drive wheel. Steering Wheel (4): Used to control the direction of travel. Speed Control Lever (5): Used to control the direction and speed of the truck. Power ON Indicator Light (6): SCR Trucks, used to indicate power is present for controls. Dynamic Brake Pushbutton (6): 12V Resistor Trucks, used to apply the dynamic brake. Manual Lowering Valve Lever (7): Used to manually lower the operator s platform and forks in case of a power loss. Emergency Power Disconnect Switch (8): Used to disengage the emergency power disconnect located inside the base and frame compartment, disconnecting all power to the truck in case of an emergency. Horn Pushbutton (9): Used to sound the horn. Hourmeter (10): Used to record the accumulated hours that electrical energy is being drawn from the battery to run the pump and drive motors. Battery Discharge Indicator (11): SCR Trucks, used to monitor the battery discharge rate to indicate the remaining battery capacity. Flasher Switch (11): 12V Resistor Trucks, used to control the optional flashing red light. Lift Limit Override Pushbutton (12): SCR Trucks, used to override the lift limit switch allowing additional lifting of the operator s platform and forks. Lift Pushbutton (2-Speed Option Not Shown) (12): 12V Resistor Trucks, used to raise and lower the operator s platform and forks. R6318 Figure 2-2 Operator s Controls - 24 Volt SCR Trucks

18 Pallet Clamp Release Lever (13): Used to secure and release the pallet on the forks. Power Steering Breather and Dipstick (14): SCR Trucks, used to allowing ventilation of the steering reservoir and check oil level. Lift/Lower Switch (15): SCR Trucks, used to raise and lower the operator s platform and forks. Fire Extinguisher (16): SCR Trucks, used to in case of an emergency OPERATION Driving and Stopping Procedures Proceed as follows to start and stop the stock selector. Refer to Figure 2-2 for SCR control trucks, or Figure 2-3 for 12 volt resistor control trucks. 1. Step on the platform facing the control console and turn the key switch (1) on. 2. Step on the brake pedal (2) to release the brake and to activate the electrical controls. 3. Note position of LEFT-RIGHT steer-wheel-position indicator. 4. Pace one hand on the steering wheel (4) and be prepared to steer the stock selector in the desired direction. 5. To move forward, slowly push the SPEED control lever (5) towards FORWARD. The stock selector will creep forward. Pushing the lever farther causes the speed to increase. 6. To stop, lift foot slowly from the brake pedal (2) as release the SPEED control lever. NOTE: Additional procedures for stopping are described in paragraph R6319 Figure 2-3 Operator s Controls - 12 Volt Resistor Trucks

19 7. To stop rapidly when an emergency exists, lift foot from brake pedal quickly. WARNING: Except in an emergency, do not stop suddenly - lift foot slowly from the brake pedal. 8. To move in reverse, step on the brake pedal and slowly pull the SPEED control lever (5) toward REVERSE. Pulling farther increases the speed. NOTE: With SCR control, the stock selector direction may be reversed while moving. The SCR control will cycle the motor to a stop and a reverse in a timed sequence without danger to the equipment. Exercise caution when doing so, especially when travelling at maximum speed Braking Following are the various methods for stopping the vehicle. Release the SPEED control lever (5) and lift your foot from the brake pedal (2). Resistor Control Only: Release the SPEED control lever (5, Figure 2-3) and press the DYNAMIC BRAKE pushbutton (6). SCR speed control stock selectors: While traveling forward, move the SPEED control lever (5, Figure 2-2) from FORWARD to REVERSE or, while traveling backward, move the SPEED control lever (5) for REVERSE to FORWARD. This can also be done with resistor speed controlled stock selectors FOR EMEERGENCIES. Release the SPEED control lever (5, Figure 2-2 or Figure 2-3) and allow the vehicle to coast to a stop Operating Lift Proceed as follows to raise and lower the lift carriage. Refer to Figure 2-2 for SCR control trucks, or Figure 2-3 for 12 volt resistor control trucks. 1. Step onto the platform and stand near the control station. NOTE: It is not necessary to release the brake. For maximum safety, leave the brake on. 2. Turn on the key switch (1). WARNING: Check the space above your head and above the entire lift carriage to be sure that the platform mast or load will not hit any obstructions while being raised. 3. Proceed as follows for 24 volt SCR trucks: a. To raise the lift carriage, activate the lift/lower switch (15, Figure 2-2). This is a three-position switch, up position raising the lift carriage, down position lowering the lift carriage, and the center position stopping the lifting/lowering process. With the two speed option, the lift/ lower switch is two separate segments, mounted side by side. Activate the left hand segment for low speed, or both segments together for high speed control. NOTE: The lift carriage will raise as long as the lift/ lower switch is in the up position, or until the lift carriage reaches maximum height. b. Return the lift/lower switch to center position when the lift carriage reaches the desired height. c. To lower the lift carriage with the speed control lever (5), position the lift/lower switch (15) in the down position, with the two speed option, lower or high speed can be selected, as described in step a. above. d. When the lift carriage reaches the desired level, return the lift/lower switch to the center position. NOTE: In the event of electrical power loss, the lift carriage may be lowered with the manual lowering valve lever (7). Slowly push the lowering lever toward DOWN. Return lever to neutral position when lift carriage reaches desired level. 4. Proceed as follows for 12 volt resistor trucks: a. To raise the lift carriage, depress the LIFT pushbutton switch (12, Figure 2-3). NOTE: The lift carriage will rise as long as the LIFT pushbutton or lever is depressed, or until the lift carriage reaches maximum height. b. Release the LIDFT pushbutton or lever when the lift carriage reaches the desired height. NOTE: The further the lowering valve is pushed toward DOWN, the faster the lift carriage will descend. This infinitely variable control permits lowering of the lift carriage with full feathering action. c. To lower the lift carriage, slowly push the lowering valve lever toward DOWN

20 d. When the lift carriage reaches the desired level, return the lowing valve lever to neutral position Fork Loading Proceed as follows to pick up or move a load on stock selectors equipped with forks. 1. Before moving stock selector, lower the lift carriage NOTE: Lowering the lift carriage lowers the stock selector center of gravity, which in turn increases the stability when traveling. 2. Move the stock selector to the pick-up area. 3. Raise forks to the desired height for entry into the pallet or skid. 4. Move into position, so that the forks are within the pallet or skid and the load is centered over the forks. 5. Move the stock selector to place load against edge of operator deck; then raise forks to lift the pallet. CAUTION: Avoid spilling the load. Move slowly and use extra care when turning. 6. Slowly move the stock selector to free load from its rack; then when load is clear of it rack, lower the load leaving enough floor clearance to maneuver. 7. Drive carefully to area where the load is to be placed. 8. Move stock selector to align load with its new position. 9. Raise loaded forks to the height desired and slowly drive into position. CAUTION: The load must rest squarely on its rack when it is lowered into position. 10. When the load is in position, lower the forks until the pallet rests on its rack and the forks are free. 11. Move backward slowly, making sure that thee forks do not catch on the pallet and lower the forks when they are clear Parking 1. To park, lift your foot from the brake pedal. This de-energizes the electrical circuits and engages the mechanical brake. 2. Turn off the key switch. 3. When finished moving loads, drive stock selector to it maintenance or storage area. Charge battery as required, see scheduled maintenance section Emergency Power Disconnect (Figure 2-2 or Figure 2-3) In an emergency, all power can be turned off at once by depressing the EMERGENCY POWER DISCON- NECT (EPD) PUSHBUTTON SWITCH (*). Once this circuit is actuated, none of the electrical controls will operate until the circuit is reset, but the lift carriage can be lowered. WARNING: Before disconnecting the battery make sure you can open the electrical compartment door to be able to reset the EPD circuit. To make the vehicle operable, the emergency power disconnect must be reset. The emergency power disconnect reset plunger is located next to the drive motor and is accessible through the electrical compartment door Pallet Clamp (Figure 2-2 or Figure 2-3) The pallet clamp is operated by the pallet clamp release lever (13). Raise the release lever to close the clamp on the center strings of the pallet being moved. The extension spiring accommodates the clamp to varying board widths. Lower the release lever to release the clamp; the spring loading of the clamp then returns the clamp arms to their idle position Moving a Disabled Truck Do not attempt to move a disabled truck. Notify your supervisor or proper authority

21 NOTES

22 3-1. GENERAL. Planned maintenance consists of periodic visual and operational checks, parts inspection, lubrication, and scheduled maintenance designed to prevent or discover malfunctions and defective parts. The operator performs the checks in SECTION 2, and refers any required servicing to a qualified maintenance technician who performs the scheduled maintenance and any required servicing. SECTION 3 PLANNED MAINTENANCE 3-2. PERIODIC CHECKS. Table 3-1 is an inspection and service chart based on normal usage of equipment eight hours per day five days per week. If the lift truck is used in excess of forty hours per week, the frequency of inspection and service should be increase accordingly. These procedures must be performed by a qualified service technician or your Big Joe service representative BATTERY CARE General. The life of the battery can be extended by giving it proper care. Perform a daily check of the battery whether or not the equipment is in daily use. DO NOT overcharge the battery or battery life will be shortened. DO NOT allow battery to become completely discharged (specific gravity or less). This will also greatly shorten battery life. Table 3-1 Monthly and Quarterly Inspection and Service Chart VISUAL CHECKS INTERVAL INSPECTION OR SERVICE Monthly Check drive motor for proper operation Monthly Check pump motor for proper operation Monthly Check brake for proper operation Monthly Check that the brake hose is securely clamped Monthly Check brake for leakage Monthly Check brake fluid level Monthly Check transmission for oil leaks Monthly Check hydraulic system for leaks Monthly Check hydraulic oil level Monthly Check load wheels for wear Monthly Check drive wheel for wear Monthly Inspect wiring for loose connections and damaged insulation Monthly Inspect contactor tips for excessive pitting and wear Monthly Check lift chain tension, lubrication & operation (See paragraph 3-5.) Monthly Lubricate unit (See Table 3-3) Quarterly Check lift cylinder for leakage Semi-annually Replace hydraulic filter assembly Semi-annually Inspect for chain wear (See paragraph 8-3.)

23 5. After charging, check water level in each cell again. Water level must cover plates but not be higher than the base of the battery cell filler neck LUBRICATION. Refer to Table 3-2 for the recommended types of grease and oil. Table 3-3 in conjunction with Figure 3-3 identifies the items requiring lubrication. Table 3-2 Recommended Lubricants (See Table 3-3 for Application) No. 1 Transmission oil EP SAE 80W-90 Transmission oil capacity is 3 pints Battery Servicing. Refer to Document 245 for battery safety and miantenance. Perform the following procedures at end of each day: 1. Obtain a battery hydrometer. NOTE: These can be obtained from a local hardware store or automotive shop. No. 2 No. 3 No. 4 Grease Lithium base, general purpose. Hydraulic oil-heavy duty with a viscosity of 150 SUS (in temperatures below 32 F use 100 SUS) foam suppressing agent and rust and oxidation inhibitors. Big Joe Part No (1 gallon) (1 quart) SAE 30 or 40 Engine lubricating oil 2. Open the battery cover and remove the vent caps. 3. Use the hydrometer to check specific gravity of each cell. NOTE: CAUTION: CAUTION: Battery specific gravity readings should agree within ±0.025 from cell to cell. If variation is greater, the battery may have to be repaired or replaced. Be sure that no cell plates are exposed (not covered by fluid) before charging. Add distilled water sufficient to just cover top of cell places. Use distilled water. Impurities in tap water will damage battery plates. 4. Charge battery as necessary. NOTE: A fully charged battery has a specific gravity of to Hydraulic System Capacity The hydraulic system capacity depends on the lift height as follows: gallons gallons gallons gallons gallons Use Big Joe Hydraulic Oil part number LIFT CHAIN MAINTENANCE. Fully raise and lower lift carriage while observing chains as they move over all chain sheaves. Ensure chain is aligned and tracking properly and all links are pivoting freely. With carriage fully lowered, spray or brush on a film of SAE 30 or 40 engine oil

24 3-6. THROTTLE CONTROL LUBRICATION The following procedure should be followed to insure proper lubrication of the throttle control lever. Silicon Grease, Big Joe Part Number , must be applied to the shaft of the throttle control lever. Access to this point requires the removal of the steering wheel and steering bar cover. 1. Remove the jam nut, Figure 3-1, securing the steering wheel and remove the steering wheel, washer, and key. 2. Remove the two screws securing the steering bar cover, then remove the cover. 3. Remove the bushing. 5. Liberally lubricate the bracket pin using Silicon Grease, Big Joe Part Number or equivalent. 6. If new parts have been incorporated, perform the Throttle Vale Adjustment Procedure provided in the SSC manual. R5877 Figure 3-1Steering Controls 4. Check for wear on the pin of the bracket, Figure 3-2, and the lever hole in the lever. If noticeably worn or hole is elongated, replace with new parts (refer to parts list in SSC manual). R5878 Figure 3-2Throttle Control 7. Reinstall the bushing, Figure Reinstall the steering bar cover and secure with the two screws. 9. Reinstall the washer, key, and steering wheel and secure with the jam nut

25 R6317 FIG 3-3 INDEX LOCATION Figure 3-3 Lubrication Diagram Table 3-3 Lubrication Chart METHOD OF APPLICATION TYPE (Table 3-3) APPLICATION OF LUBRICANT 1 Transmission Can No. 1 Fill to plug level. 2 Mast and inner mast Brush No. 2 Full length of mast where rollers touch 3 Steering sprocket assy Gun No offset drive type grease fitting. 4 Hydraulic system Can No. 3 Fill, so oil shows full on dipstick with lift carriage fully lowered. 5 All hinges Can No. 4 Oil sparingly

26 SECTION 4 TROUBLESHOOTING 4-1. GENERAL With Braking: Trouble With Lifting Or Lowering, and Oil Table 4-1 serves as a guide to determine possible Leaks. Refer to electrical wiring diagram (Figure 4-6 causes of trouble. The table is divided into five main thru Figure 4-9) as a supplement to the troubleshooting chart or when tracing an electrical circuit. categories: Truck Dead: Trouble With Travel: Trouble Table 4-1 Troubleshooting Chart MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TRUCK DEAD Truck will not run nor will lift system operate. TROUBLE WITH TRAVEL Platform operates, but drive motor will not run. Contactors do not operate Drive motor operates in only one direction. Platform operates normally. Truck will not travel at high speed with load lowered. a. 300 Amp fuse blown. Check fuse and replace if defective. b. Battery dead or disconnected. Check battery quick-disconnect plug. Check battery. c. Keyswitch defective. Bypass keyswitch to determine if it is malfunctioning. Replace if required. d. Defective wiring. Check for open circuit. Repair as required. e. Emergency power disconnect Check and reset as required. circuit off. a. Check all wiring. A loose connection may be the cause of malfunction. b. Open line to switch control. No positive voltage applied to accelerator switch. Forward or Reverse contactor does not operate. TROUBLE WITH TRAVEL (Resistor control only)* Truck runs forward and in reverse at slow speed. Will not run at higher speeds. Truck runs forward and in reverse at second or third speed only.vhicle does not move when control is in first speed position. Everything else is normal. * For SCR electrical troubleshooting see Table 4-3. High speed switch out of adjustment or defective. Defective second speed or third sped relays or both. Defective or open speed control resistor. Tighten all loose connections before further troubleshooting. Check brake switch, and contacts of all switches in the circuit for open condition. Repair or replace. Check continuity of coils, and contacts and switches in speed control. Repair or replace as required. Check operation of high speed limit switch. Adjust or replace switch as necessary. Check the soil for continuity. Check the contacts for good closure. Replace if defective. Check for clean, tight connections. Check resistor for continuity and replace or repair as required

27 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH TRAVEL (Resistor control only)* - Continued Truck runs at second or third speed when control is in the first sped position. Everything else is normal. TROUBLE WITH BRAKING Mechanical brake does not stop truck properly. Dynamic brake does not stop truck properly. Everything else is normal. (Resistor control only.)* a. Short across speed control resistor. Check wiring of resistor. Check for shorted contacts on high speed relay. b. Damaged speed control. Check switchettes in speed control. a. Brake linkage out of adjustment Adjust mechanical brake (see Paragraph 6-5.). b. Brake pads worn. Replace pads and readjust mechanical brake. Defective brake switch, brake relay, or brake resistor. If click is heard when dynamic brake pushbutton is pressed, check brake resistor and relay contracts. If no click, check brake switch and coil or relay. Repair or replace defective part. TROUBLE WITH LIFTING OR LOWERING Platform does not lift to top. Oil level too low. Lower platform completely then add oil until oil reaches full mark on dipstick. Lowering valve does not return to a. Foreign particles. Clean system and valve. neutral. b. Misalignment of valve linkage. Adjust as required. Truck runs forward and in reverse, but platform does not rise. Truck runs and platform rises, but will not go down. * For SCR electrical troubleshooting see Table 4-3. Defective electrical system for operating pump motor. Place hand against pump motor while assistant presses LIFT pushbutton. If motor runs, defect is in hydraulic system. If motor does not run, tighten electrical connections, then check LIFT pushbutton switch, the solenoid relays, and the pump motor. Repair or replace. a. Defective throttle valve. Check throttle valve. Repair or replace as required. b. Defect in hydraulic system. Look for obstruction in the hydraulic system. Repair as required. c. Defective hangup valve. Replace

28 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION Platform creeps downward under load when in raised position. Everything else is normal. Squealing sound from pump when platform is raised. Platform does not lift, motor does not run. OIL LEAKS Oil sprays or flows from top of the lift cylinder. Foaming oil in breather of hydraulic reservoir. Oil splashes out of breather when lowering platform. a. Leak in hydraulic system. Look for loose fittings on the hydraulic line. Check the check valve and pump for leakage back into the reservoir. Also check for overloading or defective relief valve in pump. Repair or replace as required. b. Lowering valve out of adjustment. Adjust valve as required. a. Oil level too low. Add oil to 1 in. of top when platform is completely lowered. b. Dry channels in mast. Apply grease. c. Defective bearing. Replace bearing. d. Pinched suction line or plugged filter. Check lines and replace filter as applicable. a. Battery is dead or disconnected. Check and recharge if required. b. Defective wiring. Check and repair as required. c. Defect in electrical system for operating pump motor. Defective packing in lift cylinder. Leak in suction line between the pump and the reservoir. Oil level to high. Check pump motor switch on lift control valve, as well as the solenoid relays. Repair or replace. Overhaul the lift cylinder and install new packing and seal. Tighten fittings. Inspect line and replace if necessary. With platform completely lowered, check that oil is up to, but not over 1 inch from top of reservoir. Table 4-2 identifies the terminal functions of the SCR and provides information on the nominal voltage at each terminal. The condition under which the voltage is measured is also specified. WARNING: All testing should be performed with the truck jacked up. Table 4-2 SCR Terminal Functions TERMINAL DESCRIPTION CONDITION NOMINAL VOLTAGE NOTE: All voltages are referenced to SCR negative. TB1 Not Used TB2 SRO and Brake Switch input. Must be high after TB3, 4 are at BV and TB5, 6 are low. Key or brake switch open 0 V

29 Table 4-2 Troubleshooting Chart - Continued TERMINAL DESCRIPTION CONDITION NOMINAL VOLTAGE TB3 Not Used TB4 Key switch input (Must go low With key switch open 0 V to reset PMT) With key switch closed Battery V TB5 REV directional switch input With key and brake switch closed and - REV in neutral 0 V - REV selected Battery V TB6 FWD directional switch input With key and brake switch closed and - FWD in neutral 0 V - FWD selected Battery V PA1 Speed Limit Switch SPD SW open 8 V (SPD SW) SPD SW closed 0 V PA2 Not Used PA3 Accelerator POT input Key switch off 0 V Key and SPD SW on and AAC POT set to - Creep position 3-4 V - TOP speed position V PA4 Not Used PA5 Not Used PA6 Not Used PB1 % on-time output Creep Speed 2.5 V Top Speed 6.5 V PB2 Motor Current sensor output 0 motor current 1.80 V 500 A avg motor current 3.30 V PB3 Not Used PB4 PMT driver output Key and brake switch closed - FWD and REV open 0 V - FWD and REV closed 5-10 M/A PB5 1A driver output NO 1A demand (1A dropped 0 out) 1A demand 0.5V) 5-10 M/A (1A closed) PB6 Plugging output Not in plugging mode 0 In plugging mode 12 V