BT Prime-Mover Forklift Komatsu Special OE-35 Trucks Electric Order Selector Quality Parts Manual  -

BT Prime-Mover Forklift Komatsu Special OE-35 Trucks Electric Order Selector Quality Parts Manual  -PDF DOWNLOAD

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BT Prime-Mover Forklift Komatsu Special OE-35 Trucks Electric Order Selector Quality Parts Manual  -PDF DOWNLOAD

Language : English,
Pages :2591
Downloadable : Yes
File Type : PDF

300206-000 1989_December   300206-009 2002_February
300206-001 1991_September
300206-002 1993_February
300206-003 1993_August
300206-004 1994_March
300206-005 1994_October
300206-006 1995_January
300206-007 1995_August
300206-008 1996_January
300206-008 1997_February
300206-008 1997_November
300206-008 1999_October

300206-009 2002_February

TABLE OF CONTENTS:

BT Prime-Mover Forklift Komatsu Special OE-35 Trucks Electric Order Selector Quality Parts Manual  -PDF DOWNLOAD

Front Cover 2
Parts Ordering Instructions 3
General Information 4
Index 6
Electrical Schematic 10
0000 Chassis 11
0300-004 Frame / chassis 12
0340-011 Inspection covers (Shields & guards) 14
0340-026 Inspection covers (Lift platform) 16
0390-006 Battery compartment parts 18
0560-001 Platform 20
0640-021 Driver controls (Brake pedal) 22
0640-022 Driver controls (Pallet clamp) 24
0640-023 Driver controls (Control handle) 26
0820-016 Finger / toe guards 28
0850-014 Signs, warnings 30
1000 Motors 31
1700-012 Drive motor (24 Volt) 32
2000 Transmission/Drive Gear 33
2550-011 Mechanical drive gear unit 34
3000 Brake/Wheel System 35
3140-000 Control valve (Steer/brake manifold) 36
3150-000 Brake cylinder 38
3300-005 Parking brake system 40
3530-007 Drive wheel 42
3550-010 Fork / support arm / outrigger wheel (Single) 44
3580-001 Guide wheel 46
4000 Steering System 47
4130-001 Orbitrol unit / steering valve (Torque generator) 48
4170-000 Steering chain / linkage / wire (Platform and mast) 50
4170-001 Steering chain / linkage / wire (Main chassis) 54
4180-008 Steering / radial bearing 56
5000 Electrical System 57
5120-002 Lights (work lights and fan) 58
5150-001 External direction indicator lights 60
5160-014 General alarm signal 62
5190-019 Battery cut-out contactor / plug (Emergency disconnect contactor) 64
5190-020 Battery cut-out contactor / plug (Battery connector) 66
5230-006 Voltage / battery indicator (LX dash display) 68
5230-007 Voltage / battery indicator (Battery lift interrupt) 70
5230-008 Voltage / battery indicator 72
5290-000 Hourmeter / speedometer 74
5310-021 Start / stop switch 76
5320-001 Travel direction switch 78
5360-007 Relay, electrical modules (Relay) 80
5390-024 Control cables / harnesses (Main chassis) 82
5390-025 Control cables / harnesses (Mast cables) 84
5390-026 Control cables / harnesses (Lift platform) 86
5400-004 Drive motor electrical system (contactor panel) 88
5410-000 SCR panel 90
5430-001 Motor cables, resistors 92
5440-002 Direction contactors (24 Volt) 94
5450-001 Speed contactors (1A) 24 Volt 96
5460-000 Transistor panel 98
5810-000 Pump motor (Lift pump) 100
6000 Hydrualic System 101
6110-004 Hydraulic tank 102
6120-009 Hoses, pipes, connections, mounting points 104
6125-022 Hoses, pipes, connections, mounting points (Two stage mast) 106
6125-023 Hoses, pipes, connections, mounting points (Three stage HIGH-VIS mast) 108
6130-010 Filters and housing 110
6140-000 Hydraulic pump 112
6210-000 Control valve (Lift/lower) 114
7000 Operating Function - Lifting Device 115
7100-000 Mast (2 stage) 116
7100-001 Mast (3 stage) 118
7110-012 Mast sections (2 stage outer column) 120
7110-013 Mast sections (2 stage inner column) 122
7110-014 Mast sections (3 stage outer column) 124
7110-015 Mast sections (3 stage intermediate column) 126
7110-016 Mast sections (3 stage inner column) 128
7170-005 Lifting gear (3 stage mast) 130
7180-000 Slack chain / emergency brake 132
7310-021 Lift cylinder (two stage mast) 134
7310-022 Lift cylinder (three stage HIGH-VIS mast staging cylinder) 136
7310-023 Lift cylinder (three stage HIGH-VIS mast Free lift cylinder) 138
8000 Peripherial equipment 139
8510-001 Driver protection 140
8520-001 Access, safety equipment (Fire extinguisher) 142
8520-002 Access, safety equipment (Safety belt, tether) 144
9000 Options/Attachments 145
9360-000 Extra lights 146
9370-000 Warning lights /alarm (Alarm) 148
9370-001 Warning lights /alarm (Blue strobe light) 150
9370-006 Warning lights /alarm (Flashing light and strobe light) 152
9500-011 Extra mechanical equipment 154
9999-001 Special tools and lubrications 156
Back Cover 157
Front Cover 158
Parts Ordering Instructions 159
General Information 160
Alphabetical Index 161
Section 00 163
Figure # 01 Decals and Parts Assembly 163
Figure # 02 Parts List Index 165
Section 10 167
Figure # 11 Transmission Installation 167
Figure # 12 Part I Transmission Assembly 169
Figure # 13 Part II Transmission Assembly 171
Section 20 173
Figure # 21 EV-100 LX Electrical Schematic 173
Figure # 22 EV-100 LX Electrical Schematic Symbols 174
Figure # 23 Wiring Diagram Part I Frame 175
Figure # 24 Mast Cable and Related Parts 177
Figure # 25 Wiring Diagram Part II Platform 179
Figure # 26 EV-100 LX Power Component Wiring 181
Figure # 27 EV-100 LX TX SCR Control Panel (49399-00) & EV-100 LX TT SCR Control Panel (49399-01) 183
Figure # 28 EV-100 LX Contactor Panel Assembly & Related Parts for "E" & "EE" 185
Figure # 29 EV-100 LX SCR Contactor Panel 187
Figure # 210 EV-100 LX SCR Forward & Rearward Contactor Assembly (27692-00) 189
Figure # 211 EV-100 LX SCR 1A Contactor Assembly (27693-02) 191
Figure # 212 EV-100 LX SCR Power Steering Contactor Assembly (300073-000) 193
Figure # 213 Lift Pump Contactor Assembly (24 Volt, 27693-02) (36 Volt, 202169) 195
Figure # 214 Emergency Disconnect Contactor Assembly (24 Volt, 300074-000) (36 Volt, 301265-000) 197
Figure # 215 Power Connector Assembly (Red, 49855-23) (Gray, 49855-20) 199
Figure # 216 24 Volt Pump Motor Assembly (J90-4001, 300282-000, Advanced) 201
Figure # 217 36 Volt Pump Motor Assembly (P90-4001, 300281-000, Advanced) 203
Figure # 218 24 Volt Drive Motor Assembly (27903-00, 5BT1322B156, GE) 205
Figure # 219 36 Volt Drive Motor Assembly (29105-00, Y91-4002, Advanced) 207
Figure # 220 24 Volt Power Steering Pump Motor Assembly (200075, Leeson, C4D17DB1C) 209
Figure # 221 Power Steering Pump Motor Assembly (301492-000, 36 Volt) (B48-1228X7832) 211
Figure # 222 Warning Light Assembly 213
Figure # 223 Wiring Assembly for Cold Storage 215
Figure # 224 EV-100 LX TT Electrical Schematic 217
Figure # 225 EV-100 LX TT Electrical Schematic Symbols 218
Figure # 226 EV-100 LX Dash Display Installation 219
Section 30 221
Figure # 31 Hydraulic Schematic 221
Figure # 32 Hydraulic Schematic Symbols 222
Figure # 33 Steering and Brake Hose Assembly 223
Figure # 34 Brake Cylinder Assembly (26468-00) 225
Figure # 35 Steering Pump and Motor Assembly (24 Volt, 26915-00) (36 Volt, 29471-00) 227
Figure # 36 Steering Pump Assembly 229
Figure # 37 Torque Generator Assembly (40795-01) 231
Figure # 38 Lift Pump, Control Valve and Related Parts 233
Figure # 39 Lift Pump and Motor Assembly 235
Figure # 310 Lift Pump Assembly (29239-00, 24 Volt) (29470-00, 36 Volt & "EE") 237
Figure # 311 Control Valve Assembly (29472-00) 239
Figure # 312 Two Stage Mast Hydraulic Cylinder and Related Parts 241
Figure # 313 Two Stage Staging Cylinder Assembly (29101-XX) 243
Figure # 314 Three Stage Mast Hydraulic Cylinder and Related Parts 245
Figure # 315 Three Stage Staging Cylinder Assembly (29101-XX) 247
Figure # 316 Three Stage Free Lift Cylinder Assembly (28150-XX) 249
Section 40 251
Figure # 41 Shielding Assembly 251
Figure # 42 Frame and Load Wheel Installation 253
Figure # 43 Platform Hand Rail Installation 255
Figure # 44 Brake Foot Pedal Installation 257
Figure # 45 Fork Mounting Installation 259
Figure # 46 Pallet Clamp Installation 261
Figure # 47 Handle Control Assembly 263
Figure # 48 Lift Platform Shielding Assembly 265
Figure # 49 Lift Platform Mast Rollers and Safety Belt 267
Figure # 410 Mast Steering Control Part # I 269
Figure # 411 Mast Steering Control Part # II 271
Figure # 412 Frame Steering Control 273
Section 50 275
Figure # 51 Two Stage Mast Installation 275
Figure # 52 Two Stage Mast Outer Column Assembly 277
Figure # 53 Two Stage Mast Inner Column Assembly 279
Figure # 54 Three Stage Mast Installation 281
Figure # 55 Three Stage Mast Outer Column Assembly 283
Figure # 56 Three Stage Mast Intermediate Column Assembly 285
Figure # 57 Three Stage Mast Inner Column Assembly 287
Figure # 58 Three Stage Mast Freelift Cylinder Installation 289
Section 60 291
Figure # 61 Work Lights and Related Parts 291
Figure # 62 Fan and Related Parts 293
Section 70 295
Figure # 71 24 Volt NDC Electrical Schematic 295
Figure # 72 24 Volt NDC Electrical Schematic Symbols 296
Figure # 73 36 Volt NDC Electrical Schematic 297
Figure # 74 36 Volt NDC Electrical Schematic Symbols 298
Figure # 75 NDC Platform Wiring Harness and Related Parts 299
Figure # 76 Mast Cable and Related Parts 301
Figure # 77 NDC Main Frame Wiring Harness and Related Parts 303
Figure # 78 Antenna and Related Parts Mounting Installation 305
Figure # 79 ACC-10 and Related Parts Installation 307
Figure # 710 Frame Steering Control and Servo-Motor Installation 309
Figure # 711 Feedback Potentiometer and Tachometer Installation 311
Figure # 712 TQA Control Box Installation 313
Section 100 315
Figure # 101 Special Tools and Lubrications 315
Numerical Index 318
Back Cover 335
Front Cover 336
Parts Ordering Instructions 337
General Information 338
Alphabetical Index 339
Section # 00 341
Figure # 01 Decals and Parts Assembly 341
Figure # 02 Parts List Index 343
Section # 10 345
Figure # 11 Transmission Installation 345
Figure # 12 Part I Transmission Assembly 347
Figure # 13 Part II Transmission Assembly 349
Section # 20 351
Figure # 21 EV-100 LX Electrical Schematic 351
Figure # 22 EV-100 LX Electrical Schematic Symbols 352
Figure # 23 Wiring Diagram Part I Frame 353
Figure # 24 Mast Cable and Related Parts 355
Figure # 25 Wiring Diagram Part II Platform 357
Figure # 26 EV-100 LX Power Component Wiring 359
Figure # 27 EV-100 LX TX/TT SCR Control Panel 361
Figure # 28 EV-100 LX Contactor Panel Assembly & Related Parts for "E" & "EE" 363
Figure # 29 EV-100 LX SCR Contactor Panel 365
Figure # 210 EV-100 LX SCR Forward & Rearward Contactor Assembly 367
Figure # 211 EV-100 LX SCR 1A Contactor Assembly 369
Figure # 212 EV-100 LX SCR Power Steering Contactor Assembly 371
Figure # 213 Lift Pump Contactor Assembly 373
Figure # 214 Emergency Disconnect Contactor Assembly 375
Figure # 215 Power Connector Assembly 377
Figure # 216 24 Volt Pump Motor Assembly 379
Figure # 217 24 Volt Lift Pump Motor Assembly 381
Figure # 218 36 Volt Pump Motor Assembly 383
Figure # 219 24 Volt Drive Motor Assembly 385
Figure # 220 36 Volt Drive Motor Assembly 387
Figure # 221 24 Volt Power Steering Pump Motor Assembly 389
Figure # 222 Power Steering Pump Motor Assembly 391
Figure # 223 Warning Light Assembly 393
Figure # 224 Wiring Assembly for Cold Storage 395
Figure # 225 EV-100 LX TT Electrical Schematic 397
Figure # 226 EV-100 LX TT Electrical Schematic Symbols 398
Figure # 227 EV-100 LX Dash Display Installation 399
Figure # 228 Battery Lift Interrupt Installation 401
Section # 30 403
Figure # 31 Hydraulic Schematic 403
Figure # 32 Hydraulic Schematic Symbols 404
Figure # 33 Steering and Brake Hose Assembly 405
Figure # 34 Brake Cylinder Assembly 407
Figure # 35 Steering Pump and Motor Assembly 409
Figure # 36 Steering Pump Assembly 411
Figure # 37 Torque Generator Assembly 413
Figure # 38 Lift Pump, Control Valve and Related Parts 415
Figure # 39 Lift Pump and Motor Assembly 417
Figure # 310 Lift Pump Assembly 419
Figure # 311 Control Valve Assembly 421
Figure # 312 Two Stage Mast Hydraulic Cylinder and Related Parts 423
Figure # 313 Two Stage Staging Cylinder Assembly 425
Figure # 314 Three Stage Mast Hydraulic Cylinder and Related Parts 427
Figure # 315 Three Stage Staging Cylinder Assembly 429
Figure # 316 Three Stage Freelift Cylinder Assembly 431
Section # 40 433
Figure # 41 Shielding Assembly 433
Figure # 42 Frame and Load Wheel Installation 435
Figure # 43 Platform Hand Rail Installation 437
Figure # 44 Brake Foot Pedal Installation 439
Figure # 45 Fork Mounting Installation 441
Figure # 46 Pallet Clamp Installation 443
Figure # 47 Handle Control Assembly 445
Figure # 48 Lift Platform Shielding Assembly 447
Figure # 49 Lift Platform Mast Rollers and Safety Belt 449
Figure # 410 Mast Steering Control Part # I 451
Figure # 411 Mast Steering Control Part # II 453
Figure # 412 Frame Steering Control 455
Section # 50 457
Figure # 51 Two Stage Mast Installation 457
Figure # 52 Two Stage Mast Outer Column Assembly 459
Figure # 53 Two Stage Mast Inner Column Assembly 461
Figure # 54 Three Stage Mast Installation 463
Figure # 55 Three Stage Mast Outer Column Assembly 465
Figure # 56 Three Stage Mast Intermediate Column Assembly 467
Figure # 57 Three Stage Mast Inner Column Assembly 469
Figure # 58 Three Stage Mast Freelift Cylinder Installation 471
Section # 60 473
Figure # 61 Work Lights and Related Parts 473
Figure # 62 Fan and Related Parts 475
Section # 70 477
Figure # 71 24 Volt NDC Electrical Schematic 477
Figure # 72 24 Volt NDC Electrical Schematic Symbols 478
Figure # 73 36 Volt NDC Electrical Schematic 479
Figure # 74 36 Volt NDC Electrical Schematic Symbols 480
Figure # 75 NDC Platform Wiring Harness and Related Parts 481
Figure # 76 Mast Cable and Related Parts 483
Figure # 77 NDC Main Frame Wiring Harness and Related Parts 485
Figure # 78 Antenna and Related Parts Mounting Installation 487
Figure # 79 Micro 70 and Related Parts Installation 489
Figure # 710 Frame Steering Control and Servo-Motor Installation 491
Figure # 711 Feedback Potentiometer and Tachometer Installation 493
Figure # 712 36 Voltage Regulator Installation 495
Section # 100 497
Figure # 101 Special Tools and Lubrications 497
Numerical Index 500
Back Cover 519
Front Cover 520
Parts Ordering Instructions 521
General Information 522
Alphabetical Index 523
Section 00 525
Figure # 01 Decals and Parts Assembly 525
Section 10 527
Figure # 11 Transmission Installation 527
Figure # 12 Part 1 Transmission Assembly 529
Figure # 13 Part 2 Transmission Assembly 531
Section 20 533
Figure # 21 EV-100 LX Electrical Schematic 533
Figure # 22 EV-100 LX Electrical Schematic Symbols 534
Figure # 23 Wiring Diagram Part 1 Frame 535
Figure # 24 Mast Cable and Related Parts 537
Figure # 25 Wiring Diagram Part 2 Platform 539
Figure # 26 EV-100 LX Power Component Wiring 541
Figure # 27 EV-100 LX TX & TTSCR Control Panel 543
Figure # 28 EV-100 LX Contactor Panel Assembly & Related Parts for "E" & "EE" 545
Figure # 29 EV-100 LX SCR Contactor Panel 547
Figure # 210 EV-100 LX SCR Forward & Rearward Contactor Assembly 549
Figure # 211 EV-100 LX SCR 1A Contactor Assembly 551
Figure # 212 EV-100 LX SCR Power Steering Contactor Assembly 553
Figure # 213 Lift Pump Contactor Assembly 555
Figure # 214 Emergency Disconnect Contactor Assembly 557
Figure # 215 Power Connector Assembly 559
Figure # 216 24 Volt Pump Motor Assembly 561
Figure # 217 24 Volt Lift Pump Motor Assembly 563
Figure # 218 36 Volt Pump Motor Assembly 565
Figure # 219 24 Volt Drive Motor Assembly 567
Figure # 220 36 Volt Drive Motor Assembly 569
Figure # 221 24 Volt Power Steering Pump Motor Assembly 571
Figure # 222 Power Steering Pump Motor Assembly 573
Figure # 223 Warning Light Assembly 575
Figure # 224 Wiring Assembly for Cold Storage 577
Figure # 225 EV-100 LX TT Electrical Schematic 579
Figure # 226 EV-100 LX TT Electrical Schematic Symbols 580
Figure # 227 EV-100 LX Dash Display Installation 581
Figure # 228 Battery Lift Interrupt Installation 583
Section 30 585
Figure # 31 Hydraulic Schematic 585
Figure # 32 Hydraulic Schematic Symbols 586
Figure # 33 Steering and Brake Hose Assembly 587
Figure # 34 Brake Cylinder Assembly 589
Figure # 35 Steering Pump and Motor Assembly 591
Figure # 36 Steering Pump Assembly 593
Figure # 37 Lift Pump, Control Valve and Related Parts 595
Figure # 38 Lift Pump and Motor Assembly 597
Figure # 39 Lift Pump Assembly 599
Figure # 310 Control Valve Assembly 601
Figure # 311 Two Stage Mast Hydraulic Cylinder and Related Parts 603
Figure # 312 Two Stage Staging Cylinder Assembly 605
Figure # 313 Three Stage Clear View Mast Hydraulic Cylinders and Related Parts 607
Figure # 314 Three Stage Clear View Mast Staging Cylinder Assembly 609
Figure # 315 Three Stage Clear View Free Lift Cylinder Assembly 611
Section 40 613
Figure # 41 Shielding Assembly 613
Figure # 42 Frame and Load Wheel Installation 615
Figure # 43 Platform Hand Rail Installation 617
Figure # 44 Brake Foot Pedal and Chain Slack Switch Installation 619
Figure # 45 Fork Mounting Installation 621
Figure # 46 Pallet Clamp Installation 623
Figure # 47 Handle Control Assembly 625
Figure # 48 Lift Platform Shielding Assembly 627
Figure # 49 Lift Platform Mast Rollers and Safety Belt 629
Figure # 410 Mast Steering Control Part # 1 631
Figure # 411 Mast Steering Control Part # 2 633
Figure # 412 Frame Steering Control 635
Figure # 413 Caster Assembly 637
Section 50 640
Figure # 51 Two Stage Mast Installation 639
Figure # 52 Two Stage Mast Outer Column Assembly 641
Figure # 53 Two Stage Mast Inner Column Assembly 643
Figure # 54 Three Stage Clear View Mast Outer Column Assembly 645
Figure # 55 Three Stage Clear View Mast Intermediate Cylinder Assembly 647
Figure # 56 Three Stage Clear View Mast Inner Column Assembly 649
Figure # 57 Three Stage Clear View Mast Freelift Cylinder Installation 651
Section 60 653
Figure # 61 Lights and Fan Assembly 653
Section 70 655
Figure # 71 24 Volt NDC Electrical Schematic 655
Figure # 72 24 Volt NDC Electrical Schematic Symbols 656
Figure # 73 36 Volt NDC Electrical Schematic 657
Figure # 74 36 Volt NDC Electrical Schematic Symbols 658
Figure # 75 NDC Platform Wiring Harness and Related Parts 659
Figure # 76 Mast Cable and Related Parts 661
Figure # 77 NDC Main Frame Wiring Harness and Related Parts 663
Figure # 78 Antenna and Related Parts Mounting Installation 665
Figure # 79 Micro 70 and Related Parts Installation 667
Figure # 710 Frame Steering Control and Servo-Motor Installation 669
Figure # 711 Feedback Potentiometer and Tachometer Installation 671
Figure # 712 36 Voltage Regulator Installation 673
Section 100 675
Figure # 101 Special Tools and Lubrications 675
Numerical Index 678
Back Cover 695
Front Cover 696
Parts Ordering Instructions 697
General Information 698
Index 699
Section 00 701
Numerical Index1386
Back Cover1407
Front Cover1408
Parts Ordering Instructions1409
General Information1410
Alphabetical Index1411
Numerical Index1562
Back Cover1579
Front Cover1580
Parts Ordering Instructions1581
Field Modifications1581
General Information1582
0000 - Chassis1587
0300-004 Frame/Chassis1588
0340-011 Inspection Covers (Shields & Guards)1590
0340-012 Inspection Covers (Lift Platform)1592
0340-017 Inspection Covers ("EE" Electrical Box)1594
0390-006 Battery Compartment Parts1596
0560-001 Platform1598
0640-021 Driver Controls (Brake Pedal)1600
0640-022 Driver Controls (Pallet Clamp)1602
0640-023 Driver Controls (Control Handle)1604
0820-016 Finger/Toe Guards1606
0850-009 Signs, Warnings1608
1000 - Drive Motor1609
1700-012 Drive Motor (24 Volt)1610
1700-013 Drive Motor (36 Volt)1612
2000 - Drive Gear/Transmission1613
2550-011 Mechanical Drive Gear Unit1614
3000 - Brake/Wheel System1615
3150-000 Brake Cylinder1616
3300-005 Parking Brake System1618
3530-007 Drive Wheel1620
3540-007 Support/Swivel Wheel1622
3550-010 Fork/Support Arm/Outrigger Wheel1624
3560-004 Stabilizer Wheel (Spring Loaded)1626
3580-001 Guide Wheel1628
4000 - Steering System1629
4130-000 Orbitrol Unit/Steering Valve (Torque Generator)1630
4150-000 Steering System Pump (Pump and Motor)1632
4150-001 Steering System Pump (Steering Pump)1634
4160-000 Servo Motor/Cylinder (NDC Wire Guidance)1636
4170-000 Steering Chain/Linkage/Wire (Platform and Mast)1638
4170-001 Steering Chain/Linkage/Wire (Main Chassis)1642
4170-002 Steering Chain/Linkage/Wire (NDC Main Chassis)1644
4180-008 Steering/Radial Bearing1646
5000 - Electrical System1647
5120-001 Lights (Work Lights and Fan)1648
5160-014 General Alarm Signal1650
5180-002 Current Collector, Cable Drum1652
5190-019 Battery Cut-Out Contactor/Plug (Emergency Disconnect Contactor)1654
5190-020 Battery Cut-Out Contactor/Plug (Battery Connector)1656
5230-006 Voltage/Battery Indicator (LX Dash Display)1658
5230-007 Voltage/Battery Indicator (Battery Lift Interrupt)1660
5230-008 Voltage/Battery Indicator1662
5290-000 Hourmeter/Speedometer1664
5310-021 Start/Stop Switch1666
5360-000 Relays, Electrical Modules (NDC Wire Guidance)1668
5390-024 Control Cables/Harnesses (Main Chassis)1670
5390-025 Control Cables/Harnesses (Mast Cables)1672
5390-026 Control Cables/Harnesses (Lift Platform)1674
5390-027 Control Cables/Harnesses (NDC Wire Guidance)1676
5390-028 Control Cables/Harnesses (NDC Wire Guidance)1678
5400-004 Drive Motor Electrical System (Contactor Panel)1680
5410-000 SCR Panel1682
5430-015 Motor Cables, Resistors1684
5440-002 Direction Contactors (24 Volt)1686
5450-001 Speed Contactors (1A) 24 Volt1688
5610-002 Pump Contactors (Lift Pump) 24 Volt1690
5610-003 Pump Contactors (Lift Pump) 36 Volt1692
5610-004 Pump Contactors (Steering Pump)1694
5760-000 Antennas (Wire Guidance)1696
5810-014 Pump Motor (Lift Pump)1698
5810-015 Pump Motor (Steering Pump, 24 Volt)1700
5810-016 Pump Motor (Steering Pump, 36 Volt)1702
6000 - Hydraulic System1703
6120-006 Hoses, Pipes, Connections, Mounting Points (Brake Hose)1704
6125-021 Hoses, Pipes, Connections, Mounting Points (Control Valve)1706
6125-022 Hoses, Pipes, Connections, Mounting Points (Two Stage Mast)1708
6125-023 Hoses, Pipes, Connections, Mounting Points (Three Stage HIGH-VIS Mast)1710
6140-008 Hydraulic Pump (Lift Pump and Motor)1712
6140-009 Hydraulic Pump (Lift Pump)1714
6160-003 Control Valve1716
7000 - Operating Function - Lifting Mast/Cylinder1717
7100-000 Mast (2 Stage)1718
7100-001 Mast (3 Stage)1720
7110-012 Mast Sections (2 Stage Outer Column)1722
7110-013 Mast Sections (2 Stage Inner Column)1724
7110-014 Mast Sections (3 Stage Outer Column)1726
7110-015 Mast Sections (3 Stage Intermediate Column)1728
7110-016 Mast Sections (3 Stage Inner Column)1730
7170-005 Lifting Gear (3 Stage Mast)1732
7180-000 Slack Chain/Emergency Brake1734
7310-021 Lift Cylinder (Two Stage Mast)1736
7310-022 Lift Cylinder (Three Stage HIGH-VIS Mast Staging Cylinder)1738
7310-023 Lift Cylinder (Three Stage HIGH-VIS Mast Free Lift Cylinder)1740
8000 - Peripheral/Installation Equipment1741
8200-000 Wire Guidance1742
8210-000 Guidance Communication Loop1744
8510-000 Driver Protection1746
8520-000 Access, Safety Equipment1748
8520-001 Access, Safety Equipment (Fire Extinguisher)1750
9000 - Options/Attachments1751
9370-006 Warning Lights/Alarm1752
9500-011 Extra Mechanical Equipment1754
9660-004 Electrical Heater1756
9999-001 Special Tools and Lubrications1758
Back Cover1759
Front Cover1760
Parts Ordering Instructions1761
General Information1762
Index1764
0000 Chassis1769
0300-004 Frame / chassis1770
0340-011 Inspection covers (Shields & guards)1772
0340-012 Inspection covers (Lift platform)1774
0340-017 Inspection covers (“EE” electrical box)1776
0390-006 Battery compartment parts1778
0560-001 Platform1780
0640-021 Driver controls (Brake pedal)1782
0640-022 Driver controls (Pallet clamp)1784
0640-023 Driver controls (Control handle)1786
0820-016 Finger / toe guards1788
0850-009 Signs, warnings1790
1000 Motor1769
1700-012 Drive motor (24 Volt)1792
1700-013 Drive motor (36 Volt)1794
2000 Transmission/Drive Gear1795
2550-011 Mechanical drive gear unit1796
3000 Brake/Wheel System1797
3150-000 Brake cylinder1798
3300-005 Parking brake system1800
3530-007 Drive wheel1802
3540-007 Support / swivel wheel1804
3550-010 Fork / support arm / outrigger wheel (Single)1806
3550-011 Fork / support arm / outrigger wheel (Tandem articulated)1808
3560-004 Stabilizer wheel (Spring loaded)1810
3580-001 Guide wheel1812
4000 Steering System1813
4130-000 Orbitrol unit / steering valve (Torque generator)1814
4150-000 Steering system pump (Pump and motor)1816
4150-001 Steering system pump (Steering pump)1818
4160-000 Servo motor / cylinder (NDC wire guidance)1820
4170-000 Steering chain / linkage / wire (Platform and mast)1822
4170-001 Steering chain / linkage / wire (Main chassis)1826
4170-002 Steering chain / linkage / wire (NDC Main chassis)1828
4180-008 Steering / radial bearing1830
5000 Electrical System1831
5120-002 Lights (work lights and fan)1832
5160-014 General alarm signal1834
5180-002 Current collector, cable drum1836
5190-019 Battery cut-out contactor / plug (Emergency disconnect contactor)1838
5190-020 Battery cut-out contactor / plug (Battery connector)1840
5230-006 Voltage / battery indicator (LX dash display)1842
5230-007 Voltage / battery indicator (Battery lift interrupt)1844
5230-008 Voltage / battery indicator1846
5290-000 Hourmeter / speedometer1848
5310-021 Start / stop switch1850
5320-001 Travel direction switch1852
5360-000 Relays, electrical modules (NDC wire guidance)1854
5390-024 Control cables / harnesses (Main chassis)1856
5390-025 Control cables / harnesses (Mast cables)1858
5390-026 Control cables / harnesses (Lift platform)1860
5390-027 Control cables / harnesses (NDC wire guidance)1862
5390-028 Control cables / harnesses (NDC wire guidance)1864
5400-004 Drive motor electrical system (contactor panel)1866
5410-000 SCR panel1868
5430-015 Motor cables, resistors1870
5440-002 Direction contactors (24 Volt)1872
5450-001 Speed contactors (1A) 24 Volt1874
5610-002 Pump contactors (Lift pump) 24 Volt1876
5610-003 Pump contactors (Lift pump) 36 Volt1878
5610-004 Pump contactors (Steering pump)1880
5760-000 Antennas (Wire guidance)1882
5810-014 Pump motor (Lift pump)1884
5810-015 Pump motor (Steering pump, 24 Volt)1886
5810-016 Pump motor (Steering pump, 36 Volt)1888
6000 Hydraulic System1889
6110-000 Hydraulic tank1890
6120-010 Hoses, pipes, connections, mounting points (Brake hose)1892
6125-022 Hoses, pipes, connections, mounting points (Two stage mast)1894
6125-023 Hoses, pipes, connections, mounting points (Three stage HIGH-VIS mast)1896
6125-045 Hoses, pipes, connections, mounting points (Control valve)1898
6130-010 Filters and housing1900
6140-008 Hydraulic pump (Lift pump and motor)1902
6140-009 Hydraulic pump (Lift pump)1904
6160-003 Control valve1906
7000 Operating Function - Lifting Device1907
7100-000 Mast (2 stage)1908
7100-001 Mast (3 stage)1910
7110-012 Mast sections (2 stage outer column)1912
7110-013 Mast sections (2 stage inner column)1914
7110-014 Mast sections (3 stage outer column)1916
7110-015 Mast sections (3 stage intermediate column)1918
7110-016 Mast sections (3 stage inner column)1920
7170-005 Lifting gear (3 stage mast)1922
7180-000 Slack chain / emergency brake1924
7310-021 Lift cylinder (two stage mast)1926
7310-022 Lift cylinder (three stage HIGH-VIS mast staging cylinder)1928
7310-023 Lift cylinder (three stage HIGH-VIS mast Free lift cylinder)1930
8000 Peripheral / Instruction Equipment1931
8200-000 Wire guidance1932
8210-000 Guidance communication loop1934
8510-000 Driver protection1936
8520-001 Access, safety equipment (Fire extinguisher)1938
8520-002 Access, safety equipment (Safety belt, tether)1940
9000 Options/Attachments1941
9360-000 Extra lights1942
9370-000 Warning lights /alarm (Alarm)1944
9370-001 Warning lights /alarm (Blue strobe light)1946
9370-006 Warning lights /alarm (Flashing light and strobe light)1948
9500-011 Extra mechanical equipment1950
9660-004 Electrical heater1952
9999-001 Special tools and lubrications1954
Back Cover1955
Front Cover1956
Parts Ordering Instructions1958
General Information1959
Index1965
0000 Chassis1970
0300-000 Frame / chassis1972
0340-000 Inspection covers (Shields & guards)1974
0340-100 Inspection covers (Lift platform)1976
0341-000 Inspection covers (“EE” electrical box)1978
0390-000 Battery compartment parts1980
0560-000 Platform1982
0640-000 Driver controls (Brake pedal)1984
0641-000 Driver controls (Pallet clamp)1986
0642-000 Driver controls (Control handle)1988
0820-000 Finger guards1990
0850-000 Decals, warnings, and manuals1992
1000 Motors1994
1710-000 Steering pump motor (24 Volt)1996
1710-100 Steering pump motor (36 Volt)1998
1730-000 Steering motor Serial number 28247001 - UP2000
1750-000 Pump motor (Lift pump)2002
1760-000 Drive motor (24 Volt)2004
1760-100 Drive motor (36 Volt)2006
2000 Transmission / Drive Gear2008
2550-000 Transmission assembly2010
3000 Brake / Wheel System2012
3150-000 Brake cylinder2014
3300-000 Parking brake system2016
3530-000 Drive wheel2018
3540-000 Swivel caster wheel2020
3550-000 Single load wheels2022
3550-100 Tandem articulated load wheels2024
3560-000 Spring loaded caster2026
3580-000 Guide wheel2028
4000 Steering System2030
4130-000 Torque generator assembly2032
4150-000 Steering pump and motor assembly2034
4151-000 Steering pump assembly2036
4170-000 2 Stage platform and mast steering linkage2038
4170-100 3 Stage platform and mast steering linkage2042
4170-200 Steering chain / linkage / wire (Main chassis)2046
4170-301 Steering chain / linkage / wire (NDC Main chassis) Serial Number 28247001 - UP2048
4180-000 Steering / radial bearing2050
5000 Electrical System2052
5120-000 Lights (work lights and fan)2054
5160-000 Horn2056
5180-000 Stick strap / chain2058
5190-000 Battery connector2060
5192-000 Battery cut-out contactor / plug (Emergency disconnect contactor)2062
5230-000 Voltage / battery indicator (LX dash display)2064
5230-100 Voltage / battery indicator (Battery lift interrupt)2066
5230-200 Voltage / battery indicator2068
5290-000 Hourmeter / speedometer2070
5310-000 Start / stop switch2072
5320-000 Travel direction switch2074
5360-000 Relays, electrical modules (NDC wire guidance)2076
5390-000 Control cables / harnesses (Main chassis)2078
5390-100 Control cables / harnesses (NDC wire guidance)2080
5391-000 Control cables / harnesses (Mast cables)2082
5392-000 Control cables / harnesses (Lift platform)2084
5392-100 Control cables / harnesses (NDC wire guidance)2086
5400-000 Contactor panel2088
5410-000 SCR panel2090
5430-000 Motor cables, resistors2092
5440-000 Direction contactor2094
5450-000 Speed contactors (1A)2096
5610-000 Pump contactors (Lift pump) 24 Volt2098
5610-100 Pump contactors (Lift pump) 36 Volt2100
5611-000 Pump contactors (Steering pump)2102
5760-000 Antennas (Wire guidance)2104
6000 Hydraulic System2106
6110-000 Hydraulic tank2108
6120-000 Hoses, pipes, connections, mounting points (Brake hose)2110
6120-100 Hoses, pipes, connections, mounting points (Control valve)2112
6125-000 Hoses, pipes, connections, mounting points (Two stage mast)2114
6125-100 Hoses, pipes, connections, mounting points (Three stage HIGH-VIS mast)2116
6130-000 Filters and housing2118
6140-000 Lift pump and motor assembly2120
6141-000 Lift pump assembly2122
6160-000 Control valve2124
6610-000 Lift cylinder (two stage mast)2126
6615-000 Lift cylinder (three stage HIGH-VIS mast staging cylinder)2128
6620-000 Lift cylinder (three stage HIGH-VIS mast Free lift cylinder)2130
7000 Operating Function - Lifting Device2132
7100-000 2 Stage mast2134
7100-100 2 Stage mast outer column2136
7100-200 2 Stage mast inner column2138
7110-000 3 Stage mast2140
7110-100 3 Stage mast outer column2142
7110-200 3 Stage mast intermediate column2144
7110-300 3 Stage mast inner column2146
7170-001 3 Stage mast lifting gear Serial Number 27135001 and UP2148
7180-000 Slack chain2150
8000 Peripheral / Installation Equipment2152
8200-000 Wire guidance controller (MICRO 70)2154
8210-000 Guidance communication loop2156
8510-000 Hand rail2158
8520-000 Fire extinguisher2160
8525-000 Safety belt, tether2162
9000 Options / Attachments2164
9360-000 Extra lights2166
9370-000 Alarm2168
9370-100 Blue warning strobe light2170
9370-200 Flashing warning light and strobe light2172
9500-000 Lift forks2174
9660-000 Electrical heater2176
10000 Tools2178
10010-000 Special tools and lubrications2180
11000 Numerical Index2182
OE35 Electical Truck Numerical Index2184
Back Cover2201
Front Cover2202
Parts Ordering Instructions2204
General Information2205
0000 Chassis2214
0300-000 Frame / chassis2216
0340-000 Inspection covers (Shields & guards)2218
0340-101 Inspection covers (Lift platform)2220
0341-000 Inspection covers (“EE” electrical box)2222
0390-000 Battery compartment parts2224
0560-000 Platform2226
0640-000 Driver controls (Brake pedal)2228
0641-001 Driver controls (Pallet clamp)2230
0642-000 Driver controls (Control handle)2232
0820-000 Finger guards2234
0850-001 Decals, warnings, and manuals2236
1000 Motors2238
1710-000 Steering pump motor (24 Volt)2240
1710-100 Steering pump motor (36 Volt)2242
1730-001 Steering motor Serial number 28247001 - UP2244
1750-000 Pump motor (Lift pump)2246
1760-000 Drive motor (24 Volt)2248
1760-100 Drive motor (36 Volt)2250
2000 Transmission / Drive Gear2252
2550-000 Transmission assembly2254
3000 Brake / Wheel System2256
3150-000 Brake cylinder2258
3300-000 Parking brake system2260
3530-000 Drive wheel2262
3540-000 Swivel caster wheel2264
3550-000 Single load wheels2266
3550-100 Tandem articulated load wheels2268
3560-000 Spring loaded caster2270
3580-000 Guide wheel2272
4000 Steering System2274
4130-000 Torque generator assembly2276
4150-000 Steering pump and motor assembly2278
4151-000 Steering pump assembly2280
4170-000 Two stage platform and mast steering linkage2282
4170-100 Three stage platform and mast steering linkage2286
4170-200 Steering chain / linkage / wire (Main chassis)2290
4170-301 Steering chain / linkage / wire (NDC Main chassis) Serial Number 28247001 - UP2292
4180-000 Steering / radial bearing2294
5000 Electrical System2296
5120-000 Lights (work lights and fan)2298
5160-000 Horn2300
5180-000 Stick strap / chain2302
5190-000 Battery connector2304
5192-000 Battery cut-out contactor / plug (Emergency disconnect contactor)2306
5230-000 Voltage / battery indicator (LX dash display)2308
5230-100 Voltage / battery indicator (Battery lift interrupt)2310
5230-200 Voltage / battery indicator2312
5290-000 Hourmeter / speedometer2314
5310-000 Start / stop switch2316
5320-000 Travel direction switch2318
5360-000 Relays, electrical modules (NDC wire guidance)2320
5390-000 Control cables / harnesses (Main chassis)2322
5390-100 Control cables / harnesses (NDC wire guidance)2324
5391-000 Control cables / harnesses (Mast cables)2326
5392-000 Control cables / harnesses (Lift platform)2328
5392-100 Control cables / harnesses (NDC wire guidance)2330
5400-000 Contactor panel2332
5410-000 SCR panel2334
5430-000 Motor cables, resistors2336
5440-000 Direction contactor2338
5450-000 Speed contactors (1A)2340
5610-000 Pump contactors (Lift pump) 24 Volt2342
5610-100 Pump contactors (Lift pump) 36 Volt2344
5611-000 Pump contactors (Steering pump)2346
5760-001 Antennas (Wire guidance) Serial number 26220001 -UP2348
6000 Hydraulic System2350
6110-000 Hydraulic tank2352
6120-000 Brake hose and steering lines2354
6120-100 Control valve and pump lines2356
6125-000 Two stage mast lines2358
6125-101 Three stage mast lines2360
6130-000 Filters and housing2362
6140-000 Lift pump and motor assembly2364
6141-000 Lift pump assembly2366
6160-000 Control valve2368
6610-000 Two stage lift cylinder2370
6615-001 Three stage staging lift cylinder Serial number OE35030314002 - UP2372
6620-000 Three stage mast freelift Lift cylinder2374
7000 Operating Function - Lifting Device2376
7100-000 Two stage mast2378
7100-100 Two stage mast outer column2380
7100-200 Two stage mast inner column2382
7110-000 Three stage mast2384
7110-100 Three stage mast outer column2386
7110-200 Three stage mast intermediate column2388
7110-300 Three stage mast inner column2390
7170-001 Three stage mast lifting gear Serial Number 27135001 and UP2392
7180-000 Slack chain2394
8000 Peripheral / Installation Equipment2396
8200-000 Wire guidance controller (MICRO 70)2398
8210-000 Guidance communication loop2400
8510-000 Hand rail2402
8520-000 Fire extinguisher2404
8525-001 Safety belt, tether2406
9000 Options / Attachments2408
9180-000 Fork extensions2410
9360-000 Extra lights2412
9370-000 Alarm2414
9370-100 Blue warning strobe light2416
9370-200 Flashing warning light and strobe light2418
9500-000 Lift forks2420
9660-001 Electrical heater2422
10000 Tools2424
10010-000 Special tools and lubrications2426
11000 Alphabetical/ Numerical Index2428
Alphabetical Index2430
Numerical Index2441
Back Cover2453
Front Cover2454
Parts Ordering Instructions2455
General Information2456
Alphabetical Index2457
Figure # 01 Decals and Parts Assembly2459
Section 002459
Figure # 02 Parts List and Service Reference Index2461
Section 102463
Figure # 11 Transmission Installation2463
Figure # 12 Part I 14:1 Transmission Assembly2465
Figure # 13 Part II 14:1 Transmission Assembly2467
Section 202469
Figure # 21 EV-100 Electrical Schematic2469
Figure # 22 Electrical Schematic Symbols2470
Figure # 23 Wiring Diagram Part # I Frame2471
Figure # 24 Mast Cable and Related Parts2473
Figure # 25 Wiring Diagram Part # II Platform2475
Figure # 26 EV-100 Power Component Wiring2477
Figure # 27 EV-100 SCR Control Panel2479
Figure # 28 EV-100 SCR Contactor Panel Assembly2481
Figure # 29 EV-100 SCR Forward & Rearward Contactor Assembly2483
Figure # 210 EV-100 1A Contactor Assembly2485
Figure # 211 EV-100 Power Steering Contactor Assembly2487
Figure # 212 EV-100 Emergency Disconnect Contactor Assembly2489
Figure # 213 Power Connector Assembly2491
Figure # 214 Lift Motor Assembly2493
Figure # 215 Drive Motor Assembly2495
Figure # 216 Power Steering Pump Motor Assembly2497
Figure # 217 Warning Light Assembly2499
Figure # 218 Wiring Assembly for Cold Storage2501
Section 302503
Figure # 31 Hydraulic Schematic2503
Figure # 32 Hydraulic Schematic Symbols2504
Figure # 33 Steering and Brake Hose Assembly2505
Figure # 34 Brake Cylinder Assembly2507
Figure # 35 Steering Pump and Motor Assembly2509
Figure # 36 Steering Pump Assembly2511
Figure # 37 Torque Generator Assembly2513
Figure # 38 Lift Pump, Control Valve and Related Parts2515
Figure # 39 Lift Pump and Motor Assembly2517
Figure # 310 Lift Pump Assembly2519
Figure # 311 Control Valve Assembly2521
Figure # 312 Two Stage Mast Hydraulic Cylinder and Related Parts2523
Figure # 313 Two Stage Staging Cylinder Assembly2525
Figure # 314 Three Stage Mast Hydraulic Cylinder and Related Parts2527
Figure # 315 Three Stage Staging Cylinder Assembly2529
Figure # 316 Three Stage Freelift Cylinder Assembly2531
Section 402533
Figure # 41 Shielding Assembly2533
Figure # 42 Frame and Load Wheel Installation2535
Figure # 43 Platform Hand Rail Installation2537
Figure # 44 Brake Foot Pedal Installation2539
Figure # 45 Fork Mounting Installation2541
Figure # 46 Pallet Clamp Installation2543
Figure # 47 Handle Control Assembly2545
Figure # 48 Lift Platform Shielding Assembly2547
Figure # 49 Lift Platform Mast Rollers and Safety Belt2549
Figure # 410 Mast Steering Control Part # I2551
Figure # 411 Mast Steering Control Part # II2553
Figure # 412 Frame Steering Control2555
Section 502557
Figure # 51 Two Stage Mast Installation2557
Figure # 52 Two Stage Outer Column Assembly2559
Figure # 53 Two Stage Inner Column Assembly2561
Figure # 54 Three Stage Mast Installation2563
Figure # 55 Three Stage Outer Column Assembly2565
Figure # 56 Three Stage Intermediate Column Assembly2567
Figure # 57 Three Stage Inner Column Assembly2569
Figure # 58 Three Stage Freelift Cylinder Installation2571
Section 602573
Figure # 61 Special Tools and Lubrications2573
Numerical Index2576
Back Cover2591

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