BT Prime-Mover Forklift RR-45RR-45Z ELECTRIC REACH TRUCK PART MANUAL

BT Prime-Mover Forklift RR-45/RR-45Z ELECTRIC REACH TRUCK PART MANUAL – PDF DOWNLOAD

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BT Prime-Mover Forklift RR-45/RR-45Z ELECTRIC REACH TRUCK PART MANUAL – PDF DOWNLOAD

Language : English,
Pages :1352
Downloadable : Yes
File Type : PDF

Serial Number 238728

TABLE OF CONTENTS:

BT Prime-Mover Forklift RR-45/RR-45Z ELECTRIC REACH TRUCK PART MANUAL – PDF DOWNLOAD

Front Cover 1
Parts Ordering Instructions 2
General Information 3
Alphabetical Index 4
Figure # 01 Decals and Parts Assembly 8
Figure # 11 Transmission and Steering Installation 10
Figure # 12 Drive Motor & Related Parts 12
Figure # 13 Transmission Assembly Part # I 14
Figure # 14 Transmission Assembly Part # II 16
Figure # 21 TX Electrical Schematic – Multi-Function Control 18
Figure # 22 TT Electrical Schematic – Multi-Function Control 19
Figure # 23 “Z” Lift TX Electrical Schematic – Multi-Function Control 20
Figure # 24 “Z” Lift TT Electrical Schematic – Multi-Function Control 21
Figure # 25 Wiring Assembly for Cold Storage 22
Figure # 26 Lift Control Wiring Harness – Multi-Function Control 24
Figure # 27 Limit Switch Wiring Assembly 26
Figure # 28 Two Stage Mast Cable Assembly 28
Figure # 29 Three Stage Mast Cable Assembly 30
Figure # 210 Reach Cable Assembly 32
Figure # 211 Power Component Wiring 34
Figure # 212 SCR Control Panel 36
Figure # 213 “Z” Lift Contactor Panel Assembly & Related Parts 38
Figure # 214 Contactor Panel Assembly & Related Parts for “E” and “EE” 40
Figure # 215 Contactor Panel Assembly 42
Figure # 216 Forward & Rearward Contactor Assembly 44
Figure # 217 Contactor Assembly 46
Figure # 218 Power Connector Assembly 48
Figure # 219 Lift Pump Motor Assembly 50
Figure # 220 Drive Motor Assembly 52
Figure # 221 Auxiliary Pump Motor Assembly 54
Figure # 222 Warning Light and Work Light Assembly 56
Figure # 223 EV-100LX Dash Display Installation 58
Figure # 224 “E” Electrical Schematic – Single Function Control 60
Figure # 225 “EE” Electrical Schematic – Single Function Control 61
Figure # 226 “Z” Lift Electrical Schematic – Single Function Control 62
Figure # 227 Electrical Schematic Symbols 63
Figure # 228 Lift Control Wiring Harness – Single Function Control 64
Figure # 229 Battery Lift Interrupt Installation 66
Figure # 31 Hydraulic Schematic 68
Figure # 32 Hydraulic Schematic Symbols 69
Figure # 33 Auxiliary Pump & Reservoir Assembly 70
Figure # 34 Auxiliary Control Valve & Related Parts 72
Figure # 35 Two Stage Mast Hydraulic Assembly 74
Figure # 36 Three Stage Mast Hydraulic Assembly 76
Figure # 37 Single Reach, Reach Cylinder Hose Installation 78
Figure # 38 Single Reach, Tilt and Sideshift Hose Installation 80
Figure # 39 Double Reach with Tilt and Sideshifter 82
Figure # 310 Steering Control Valve and Hose Assembly 84
Figure # 311 Steering Cylinder Assembly 86
Figure # 312 Lift Pump and Reservoir Assembly – Single Pump 88
Figure # 313 “Z” Lift Pump Motor and Reservoir Assembly – Double Pump 90
Figure # 314 Two Stage Cylinder and Reservoir Assembly 92
Figure # 315 Two Stage Cylinder Assembly 94
Figure # 316 Three Stage Cylinder & Reservoir Assembly – Single Pump 96
Figure # 317 Three Stage Cylinder & Reservoir Assembly, “Z” Lift – Double Pump 98
Figure # 318 Three Stage Staging Cylinder Assembly 100
Figure # 319 Three Stage Freelift Cylinder Assembly 102
Figure # 320 Hydraulic Reservoir Assembly 104
Figure # 321 Auxiliary Control Valve Assembly – Single Function Control 106
Figure # 322 Lift Control Valve Assembly 108
Figure # 323 Valve Assembly – Multi-Function Control 110
Figure # 324 Single Reach Diverter Valve Assembly 112
Figure # 325 Double Reach Diverter Valve Assembly 114
Figure # 326 Steering Control Valve Assembly 116
Figure # 327 Lift Pump & Motor Assembly 118
Figure # 328 Lift Pump Assembly 120
Figure # 329 Lift Pump Assembly, 36 Volt “E” – Single Pump 122
Figure # 330 Auxiliary Pump and Motor Assembly 124
Figure # 331 Auxiliary Pump Assembly 126
Figure # 332 Reach Cylinder Assembly 128
Figure # 333 Tilt Cylinder Assembly 130
Figure # 334 Brake Linkage and Cylinder Assembly 132
Figure # 335 Brake Master Cylinder 134
Figure # 336 Drive Motor Brake Cylinder 136
Figure # 337 Idler Wheel Brake Cylinder 138
Figure # 41 Shielding Assembly 140
Figure # 42 Emergency Disconnect Assembly 142
Figure # 43 Auxiliary Control Assembly – Single Function Control 144
Figure # 44 Hand Lift/Lower and Speed Control – Multi-Function Control 146
Figure # 45 Hand Lift/Lower and Speed Control – Single Function Control 148
Figure # 46 Steering Control Assembly 150
Figure # 47 Idler Wheel Installation 152
Figure # 48 Idler Wheel Assembly 154
Figure # 49 Main Frame and Load Wheel Assembly 156
Figure # 410 5″ High Articulating Load Wheel Assembly 158
Figure # 411 Single Load Wheel Assembly 160
Figure # 412 4″ High Articulating Load Wheel Assembly 162
Figure # 51 Two Stage Mast Installation 164
Figure # 52 Two Stage Inner Column Assembly 166
Figure # 53 Two Stage Outer Column Assembly 168
Figure # 54 Two Stage Cylinder Installation 170
Figure # 55 Three Stage Mast Installation 172
Figure # 56 Three Stage Inner Column Assembly 174
Figure # 57 Three Stage Freelift Cylinder Installation 176
Figure # 58 Three Stage Intermediate Column Assembly 178
Figure # 59 Three Stage Outer Column Assembly 180
Figure # 510 Single Reach Assembly 182
Figure # 511 Single Reach Front Frame Assembly 184
Figure # 512 Double Reach Assembly 186
Figure # 513 Double Reach Front Frame Assembly 188
Figure # 514 Sideshifter Assembly 190
Figure # 515 Fork Assembly 192
Figure # 101 Special Tools and Lubrications 194
Numerical Index 197
Back Cover 218
Front Cover 219
Parts Ordering Instructions 220
General Information 221
Alphabetical Index 222
Figure # 01 Decals and Parts Assembly 226
Figure # 11 Transmission and Steering Installation 228
Figure # 12 Drive Motor & Related Parts 230
Figure # 13 Transmission Assembly Part # I 232
Figure # 14 Transmission Assembly Part II 234
Figure # 21 TX Electrical Schematic – Multi-Function Control 236
Figure # 22 TT Electrical Schematic – Multi-Function Control 237
Figure # 23 “Z” Lift TX Electrical Schematic – Multi-Function Control 238
Figure # 24 “Z” Lift TT Electrical Schematic – Multi-Function Control 239
Figure # 25 Wiring Assembly for Cold Storage 240
Figure # 26 Lift Control Wiring Harness – Multi-Function Control 242
Figure # 27 Limit Switch Wiring Assembly 244
Figure # 28 Two Stage Mast Cable Assembly 246
Figure # 29 Three Stage Mast Cable Assembly 248
Figure # 210 Reach Cable Assembly 250
Figure # 211 Power Component Wiring 252
Figure # 212 SCR Control Panel 254
Figure # 213 “Z” Lift Contactor Panel Assembly & Related Parts 256
Figure # 214 Contactor Panel Assembly & Related Parts for “E” and “EE” 258
Figure # 215 Contactor Panel Assembly 260
Figure # 216 Forward & Rearward Contactor Assembly 262
Figure # 217 Contactor Assembly 264
Figure # 218 Power Connector Assembly 266
Figure # 219 Lift Pump Motor Assembly 268
Figure # 220 Drive Motor Assembly 270
Figure # 221 Auxiliary Pump Motor Assembly 272
Figure # 222 Warning Light and Work Light Assembly 274
Figure # 223 EV-100LX Dash Display Installation 276
Figure # 224 “E” Electrical Schematic – Single Function Control 278
Figure # 225 “EE” Electrical Schematic – Single Function Control 279
Figure # 226 “Z” Lift Electrical Schematic – Single Function Control 280
Figure # 227 Electrical Schematic Symbols 281
Figure # 228 Lift Control Wiring Harness – Single Function Control 282
Figure # 229 Battery Lift Interrupt Installation 284
Figure # 31 Hydraulic Schematic 286
Figure # 32 Hydraulic Schematic Symbols 287
Figure # 33 Auxiliary Pump & Reservoir Assembly 288
Figure # 34 Auxiliary Control Valve & Related Parts 290
Figure # 35 Two Stage Mast Hydraulic Assembly 292
Figure # 36 Three Stage Mast Hydraulic Assembly 294
Figure # 37 Single Reach, Reach Cylinder Hose Installation 296
Figure # 38 Single Reach, Tilt and Sideshift Hose Installation 298
Figure # 39 Double Reach with Tilt and Sideshifter 300
Figure # 310 Steering Control Valve and Hose Assembly 302
Figure # 311 Steering Cylinder Assembly 304
Figure # 312 Lift Pump and Reservoir Assembly – Single Pump 306
Figure # 313 “Z” Lift Pump Motor and Reservoir Assembly – Double Pump 308
Figure # 314 Two Stage Cylinder and Reservoir Assembly 310
Figure # 315 Two Stage Cylinder Assembly 312
Figure # 316 Three Stage Cylinder & Reservoir Assembly – Single Pump 314
Figure # 317 Three Stage Cylinder & Reservoir Assembly, “Z” Lift – Double Pump 316
Figure # 318 Three Stage Staging Cylinder Assembly 318
Figure # 319 Three Stage Freelift Cylinder Assembly 320
Figure # 320 Hydraulic Reservoir Assembly 322
Figure # 321 Auxiliary Control Valve Assembly – Single Function Control 324
Figure # 322 Lift Control Valve Assembly 326
Figure # 323 Valve Assembly – Multi-Function Control 328
Figure # 324 Single Reach Diverter Valve Assembly 330
Figure # 325 Double Reach Diverter Valve Assembly 332
Figure # 326 Steering Control Valve Assembly 334
Figure # 327 Lift Pump & Motor Assembly 336
Figure # 328 Lift Pump Assembly 338
Figure # 329 Lift Pump Assembly, 36 Volt “E” – Single Pump 340
Figure # 330 Auxiliary Pump and Motor Assembly 342
Figure # 331 Auxiliary Pump Assembly 344
Figure # 332 Reach Cylinder Assembly 346
Figure # 333 Tilt Cylinder Assembly 348
Figure # 334 Brake Linkage and Cylinder Assembly 350
Figure # 335 Brake Master Cylinder 352
Figure # 336 Drive Motor Assembly 354
Figure # 337 Idler Wheel Brake Cylinder 356
Figure # 41 Shielding Assembly 358
Figure # 42 Emergency Disconnect Assembly 360
Figure # 43 Auxiliary Control Assembly – Single Function Control 362
Figure # 44 Hand Lift/Lower and Speed Control – Multi-Function Control 364
Figure # 45 Hand Lift/Lower and Speed Control – Single Function Control 366
Figure # 46 Steering Control Assembly 368
Figure # 47 Idler Wheel Installation 370
Figure # 48 Idler Wheel Assembly 372
Figure # 49 Main Frame and Load Wheel Assembly 374
Figure # 410 5″ High Articulating Load Wheel Assembly 376
Figure # 411 Single Load Wheel Assembly 378
Figure # 412 4″ High Articulating Load Wheel Assembly 380
Figure # 51 Two Stage Mast Installation 382
Figure # 52 Two Stage Inner Column Assembly 384
Figure # 53 Two Stage Outer Column Assembly 386
Figure # 54 Two Stage Cylinder Installation 388
Figure # 55 Three Stage Mast Installation 390
Figure # 56 Three Stage Inner Column Assembly 392
Figure # 57 Three Stage Freelift Cylinder Installation 394
Figure # 58 Three Stage Intermediate Column Assembly 396
Figure # 59 Three Stage Outer Column Assembly 398
Figure # 510 Single Reach Assembly 400
Figure # 511 Single Reach Front Frame Assembly 402
Figure # 512 Double Reach Assembly 404
Figure # 513 Double Reach Front Frame Assembly 406
Figure # 514 Sideshifter Assembly 408
Figure # 515 Fork Assembly 410
Figure # 101 Special Tools and Lubrications 412
Numerical Index 415
Back Cover 440
Front Cover 441
Parts Ordering Instructions 442
General Information 443
Figure # 01 Decal and Parts Assembly 444
Figure # 02 Parts List and Figure Number Index 446
Figure # 11 Transmission and Steering Installation 448
Figure # 12 Drive Motor and Brake Assembly 450
Figure # 13 Transmission Assembly Part # 1 452
Figure # 14 Transmission Assembly Part # 2 454
Figure # 21 RR45Z “Z” Lift EV-100LX SCR Electrical Schematic 456
Figure # 22 SCR Electrical Schematic Symbols 457
Figure # 23 Wiring Assembly for Cold Storage 458
Figure # 24 Control Wiring Harness and Related Parts 460
Figure # 25 Limit Switch Wiring Harness Assembly 462
Figure # 26 Three Stage Mast Cable Assembly 464
Figure # 27 Single Reach Cable Assembly 466
Figure # 28 Double Reach Cable Assembly 468
Figure # 29 EV-100LX Power Component Wiring 470
Figure # 210 EV-100LX TX & TT SCR Control Panel 472
Figure # 211 Contactor Panel Assembly & Related Parts 474
Figure # 212 EV-100LX Contactor Panel Assembly 476
Figure # 213 Forward & Rearward Contactor Assembly 478
Figure # 214 1A Contactor Assembly 480
Figure # 215 Lift Pump Contactor Assembly 482
Figure # 216 Auxiliary Pump Contactor Assembly 484
Figure # 217 Power Connector Assembly 486
Figure # 218 Lift Pump Motor Assembly 488
Figure # 219 Drive Motor Assembly 490
Figure # 220 Auxiliary Pump Motor Assembly 492
Figure # 221 Warning Light Assembly 494
Figure # 222 EV-100LX TT Electrical Schematic 496
Figure # 223 EV-100LX TT Electrical Schematic Symbols 497
Figure # 224 EV-100LX Dash Display Installation 498
Figure # 31 RR45Z “Z” Lift EV-100LX Hydraulic Schematic 500
Figure # 32 Hydraulic Schematic Symbols 501
Figure # 33 Auxiliary Pump and Reservoir Assembly 502
Figure # 34 Auxiliary Control Valve Assembly 504
Figure # 35 Auxiliary Pump Assembly 506
Figure # 36 Hydraulic Reservoir Assembly 508
Figure # 37 Steering Control Valve Assembly 510
Figure # 38 Steering Control Valve and Hose Assembly 512
Figure # 39 Steering Cylinder Assembly 514
Figure # 310 “Z” Lift EV-100LX Three Stage Mast Hydraulic Assembly 516
Figure # 311 Single Reach, Reach Cylinder Hose Installation 518
Figure # 312 Single Reach Diverter Valve Assembly 520
Figure # 313 Single Reach, Reach Cylinder Assembly 522
Figure # 314 Single Reach, Tilt and Sideshifter 524
Figure # 315 Single Reach, Tilt Cylinder Assembly 526
Figure # 316 Double Reach with Tilt and Sideshifter 528
Figure # 317 Double Reach Diverter Valve Assembly 530
Figure # 318 Double Reach, Reach Cylinder Assembly 532
Figure # 319 Double Reach, Tilt Cylinder Assembly 534
Figure # 320 Lift Pump and Reservoir Assembly 536
Figure # 321 Lift Pump and Motor Assembly 538
Figure # 322 Lift Pump Assembly 540
Figure # 323 Lift Control Valve Assembly 542
Figure # 324 Three Stage Cylinder and Reservoir Assembly 544
Figure # 325 Three Stage Staging Cylinder Assembly 546
Figure # 326 Three Stage Freelift Cylinder Assembly 548
Figure # 327 Brake Master Cylinder 550
Figure # 328 Drive Motor Brake Cylinder 552
Figure # 329 Idler Wheel Brake Cylinder 554
Figure # 41 Shielding Assembly 556
Figure # 42 Emergency Disconnect Assembly 558
Figure # 43 Auxiliary Control Assembly 560
Figure # 44 Hand Lift/Lower and Speed Control 562
Figure # 45 Brake Linkage and Cylinder Assembly 564
Figure # 46 Steering Control Assembly 566
Figure # 47 Idler Wheel Installation 568
Figure # 48 Idler Wheel Assembly 570
Figure # 49 Main Frame and Load Wheel 572
Figure # 410 Single Load Wheel Assembly 574
Figure # 411 5″ High Articulating Load Wheel Assembly 576
Figure # 412 4″ High Articulating Load Wheel 578
Figure # 51 Three Stage Mast Installation 580
Figure # 52 Three Stage Inner Column Assembly 582
Figure # 53 Three Stage Freelift Cylinder Installation 584
Figure # 54 Three Stage Intermediate Column Assembly 586
Figure # 55 Three Stage Outer Column Assembly 588
Figure # 56 Single Reach Assembly 590
Figure # 57 Single Reach with Front Frame 592
Figure # 58 Double Reach Assembly 594
Figure # 59 Double Reach with Front Frame 596
Figure # 510 Sideshifter Assembly 598
Figure # 511 Fork Assembly 600
Figure # 71 Special Tools and Lubrications 602
Numerical Index 605
Back Cover 626
Front Cover 627
Parts Ordering Instructions 628
Field Modifications 628
General Information 629
Alphabetical Index 630
Figure # 01 Decals and Parts Assembly 634
Figure # 11 Transmission and Steering Installation 636
Figure # 12 Drive Motor Brake Assembly 638
Figure # 13 Transmission Assembly Part # 1 640
Figure # 14 Transmission Assembly Part # 2 642
Figure # 21 RR45Z “Z” Lift EV-100LX SCR Electrical Schematic 644
Figure # 22 RR45Z “Z” Lift EV-100LX SCR Electrical Schematic Symbols 645
Figure # 23 Wiring Assembly for Cold Storage 646
Figure # 24 RR45Z “Z” Lift Control Wiring Harness 648
Figure # 25 Limit Switch Wiring Assembly 650
Figure # 26 Three Stage Mast Cable Assembly 652
Figure # 27 Single Reach Cable Assembly 654
Figure # 28 Double Reach Cable Assembly 656
Figure # 29 EV-100LX Power Component Wiring 658
Figure # 210 EV-100LX TX & TT SCR Control Panel Assembly 660
Figure # 211 Contactor Panel Assembly & Related Parts 662
Figure # 212 EV-100LX Contactor Panel Assembly 664
Figure # 213 EV-100LX SCR Forward & Rearward Contactor Assembly 666
Figure # 214 EV-100LX SCR 1A Contactor Assembly 668
Figure # 215 Lift Pump Contactor Assembly 670
Figure # 216 EV-100LX SCR Auxiliary Pump Contactor Assembly 672
Figure # 217 Power Connector Assembly, 36 Volt 674
Figure # 218 Lift Pump Motor Assembly 676
Figure # 219 Drive Motor Assembly 678
Figure # 220 Auxiliary Pump Motor Assembly 680
Figure # 221 Warning Light Assembly 682
Figure # 222 EV-100LX TT Electrical Schematic 684
Figure # 223 EV-100LX TT Electrical Schematic Symbols 685
Figure # 224 EV-100LX Dash Display Installation 686
Figure # 225 EV-100LX SCR Electrical Schematic – 3 Function Control Handle 688
Figure # 226 EV-100LX SCR Electrical Schematic Symbols 689
Figure # 227 Wiring Harness Assembly for 3 Function Control Valve 690
Figure # 230 RR45 “Z” EV-100LX TT SCR Electrical Schematic – Three Function Control Handle 692
Figure # 231 EV-100LX SCR Electrical Schematic Symbols 693
Figure # 31 Hydraulic Schematic for 3 Function Control Handle 694
Figure # 32 Hydraulic Schematic Symbols 695
Figure # 33 Auxiliary Pump and Reservoir Assembly 696
Figure # 34 Auxiliary Control Valve Assembly (not used with multi-function handle) 698
Figure # 35 Auxiliary Pump and Motor Assembly 700
Figure # 36 Auxiliary Pump Assembly 702
Figure # 37 Hydraulic Reservoir Assembly 704
Figure # 38 Steering Control Valve Assembly 706
Figure # 39 Steering Control Valve and Hose Assembly 708
Figure # 310 Steering Cylinder Assembly 710
Figure # 311 Three Stage Mast Hydraulic Assembly 712
Figure # 312 Single Reach, Reach Cylinder Hose Installation 714
Figure # 313 Single Reach Diverter Valve Assembly 716
Figure # 314 Single Reach, Cushion Reach Cylinder Assembly 718
Figure # 315 Single Reach, Tilt and Sideshift Hose Installation 720
Figure # 316 Double Reach with Tilt and Sideshifter 722
Figure # 317 Double Reach, Reach Cylinder Assembly 724
Figure # 318 Double Reach Diverter Valve Assembly 726
Figure # 319 Double Reach, Tilt Cylinder Assembly 728
Figure # 320 Double Reach, Reach Cylinder Assembly 730
Figure # 321 Double Reach, Tilt Cylinder Assembly 732
Figure # 322 Lift Pump Motor and Reservoir Assembly 734
Figure # 323 Lift Pump Motor Assembly 736
Figure # 324 Lift Pump Motor Assembly, 24 Volt 738
Figure # 325 Lift Pump Motor Assembly, 36 Volt 740
Figure # 326 Lift Control Valve Assembly 742
Figure # 327 Three Stage Cylinder and Reservoir Assembly 744
Figure # 328 Three Stage Staging Cylinder Assembly 746
Figure # 329 Three Stage Freelift Cylinder Assembly 748
Figure # 330 Brake Linkage and Cylinder Assembly 750
Figure # 331 Brake Master Cylinder 752
Figure # 332 Drive Motor Brake Cylinder 754
Figure # 333 Idler Wheel Brake Cylinder 756
Figure # 336 Auxiliary Pump & Reservoir Assembly for 3 Function Control Handle 758
Figure # 337 Valve Assembly 760
Figure # 338 Three Stage Mast Hydraulic Assembly for 3 Function Control Handle 762
Figure # 41 Shielding Assembly 764
Figure # 42 Emergency Disconnect Assembly 766
Figure # 43 Auxiliary Control Assembly 768
Figure # 44 Hand Lift/Lower and Speed Control 770
Figure # 45 Steering Control Assembly 772
Figure # 46 Idler Wheel Installation 774
Figure # 47 Idler Wheel Assembly 776
Figure # 48 Main Frame and Load Wheel Assembly 778
Figure # 49 Single Load Wheel Assembly 780
Figure # 410 5″ High Articulating Load Wheel Assembly 782
Figure # 411 4″ High Articulating Load Wheel Assembly 784
Figure # 413 Hand Lift/Lower and Speed Control for 3 Function Control 786
Figure # 51 Three Stage Mast Installation 788
Figure # 52 Three Stage Inner Column Assembly 790
Figure # 53 Three Stage Freelift Cylinder Installation 792
Figure # 54 Three Stage Intermediate Column Assembly 794
Figure # 55 Three Stage Outer Column Assembly 796
Figure # 56 Single Reach Assembly 798
Figure # 57 Single Reach with Front Frame 800
Figure # 58 Double Reach Assembly 802
Figure # 59 Double Reach with Front Frame 804
Figure # 510 Sideshifter Assembly 806
Figure # 511 Fork Assembly 808
Figure # 61 Manlift EV-100 LX SCR Electrical Schematic 810
Figure # 62 Manlift EV-100 LX SCR Electrical Schematic Symbols 811
Figure # 63 Manlift Wiring Harness Assembly 812
Figure # 64 Manlift Three Stage Mast Cable Assembly 814
Figure # 65 Manlift Reach and Platform Cable Assembly 816
Figure # 66 Manlift Power Component Wiring 818
Figure # 67 Manlift Connector Assembly 820
Figure # 68 Manlift Hydraulic Schematic 822
Figure # 69 Manlift Hydraulic Schematic Symbols 823
Figure # 610 Manlift Hydraulic Diagram 824
Figure # 611 Blocking Manlift Valve Assembly 826
Figure # 612 Manlift Valve Assembly 828
Figure # 613 Manlift Load Backrest Installation 830
Figure # 101 Special Tools and Lubrications 832
Numerical Index 835
Back Cover 854
Front Cover 855
Parts Ordering Instructions 856
General Information 857
Alphabetical Index 858
Figure # 01 Decals and Parts Assembly 862
Figure # 11 Transmission and Steering Installation 864
Figure # 12 Drive Motor Brake Assembly 866
Figure # 13 Transmission Assembly, Part # I 868
Figure # 14 Transmission Assembly, Part # II 870
Figure # 21 EV-100LX SCR Electrical Schematic 872
Figure # 22 EV-100LX SCR Electrical Schematic Symbols 873
Figure # 23 Wiring Assembly for Cold Storage 874
Figure # 24 Lift Control Wiring Harness 876
Figure # 25 Limit Switch Wiring Assembly 878
Figure # 26 Three Stage Mast Cable Assembly 880
Figure # 27 Single Reach Cable Assembly 882
Figure # 28 Double Reach Cable Assembly 884
Figure # 29 EV-100LX Power Component Wiring 886
Figure # 210 EV-100LX TX & TT SCR Control Panel Assembly 888
Figure # 211 Contactor Panel Assembly & Related Parts 890
Figure # 212 EV-100LX Contactor Panel Assembly 892
Figure # 213 EV-100LX SCR Forward & Rearward Contactor Assembly 894
Figure # 214 EV-100LX SCR 1A Contactor Assembly 896
Figure # 215 Lift Pump Contactor Assembly 898
Figure # 216 EV-100LX SCR Auxiliary Pump Contactor Assembly 900
Figure # 217 Power Connector Assembly, 36 Volt 902
Figure # 218 Lift Pump Motor Assembly 904
Figure # 219 Drive Motor Assembly 906
Figure # 220 Auxiliary Pump Motor Assembly 908
Figure # 221 Warning Light Assembly 910
Figure # 222 EV-100LX TT SCR Electrical Schematic 912
Figure # 223 EV-100LX TT SCR Electrical Schematic Symbols 913
Figure # 224 EV-100LX Dash Display Installation 914
Figure # 225 TT SCR Electrical Schematic Three Function Control Handle 916
Figure # 226 EV-100LX SCR Electrical Schematic Symbols 917
Figure # 227 Wiring Harness Assembly for 3 Function Control Valve 918
Figure # 31 Hydraulic Schematic for 3 Function Control Handle 920
Figure # 32 Hydraulic Schematic Symbols 921
Figure # 33 Auxiliary Pump and Reservoir Assembly 922
Figure # 34 Auxiliary Control Valve Assembly 924
Figure # 35 Auxiliary Pump and Motor Assembly, 36 Volt 926
Figure # 36 Auxiliary Pump Assembly 928
Figure # 37 Hydraulic Reservoir Assembly 930
Figure # 38 Steering Control Valve Assembly 932
Figure # 39 Steering Control Valve and Hose Assembly 934
Figure # 310 Steering Cylinder Assembly 936
Figure # 311 Three Stage Mast Hydraulic Assembly 938
Figure # 312 Single Reach, Reach Cylinder Hose Installation 940
Figure # 313 Single Reach Diverter Valve Assembly 942
Figure # 314 Single Reach, Reach Cylinder Assembly 944
Figure # 315 Single Reach, Tilt and Sideshift Hose Installation 946
Figure # 316 Single Reach, Tilt Cylinder Assembly 948
Figure # 317 Double Reach with Tilt and Sideshifter 950
Figure # 318 Double Reach Diverter Valve Assembly 952
Figure # 319 Double Reach, Reach Cylinder Assembly 954
Figure # 320 Double Reach, Tilt Cylinder Assembly 956
Figure # 321 Lift Pump Motor and Reservoir Assembly 958
Figure # 322 Lift Pump Motor Assembly 960
Figure # 323 Lift Pump Assembly 962
Figure # 324 Lift Control Valve Assembly 964
Figure # 325 Three Stage Cylinder and Reservoir Assembly 966
Figure # 326 Three Stage Staging Cylinder Assembly 968
Figure # 327 Three Stage Freelift Cylinder Assembly 970
Figure # 328 Brake Linkage and Cylinder Assembly 972
Figure # 329 Brake Master Cylinder 974
Figure # 330 Drive Motor Brake Cylinder 976
Figure # 331 Idler Wheel Brake Cylinder 978
Figure # 332 Auxiliary Pump & Reservoir Assy for 3 Function Control Handle 980
Figure # 333 Valve Assembly 982
Figure # 334 Three Stage Mast Hydraulic Assembly for 3 Function Control Handle 984
Figure # 41 Shielding Assembly 986
Figure # 42 Emergency Disconnect Assembly 988
Figure # 43 Auxiliary Control Assembly 990
Figure # 44 Hand Lift/Lower and Speed Control 992
Figure # 45 Steering Control Assembly 994
Figure # 46 Idler Wheel Installation 996
Figure # 47 Idler Wheel Assembly 998
Figure # 48 Main Frame and Load Wheel Assembly1000
Figure # 49 Single Load Wheel Assembly1002
Figure # 49A Single Load Wheel Assembly1004
Figure # 410 5″ High Articulating Load Wheel Assembly1006
Figure # 410A 5″ High Articulating Load Wheel Assembly1008
Figure # 411 4″ High Articulating Load Wheel Assembly1010
Figure # 411A 4″ High Articulating Load Wheel Assembly1012
Figure # 412 Hand Lift/Lower and Speed Control for 3 Function Control1014
Figure # 51 Three Stage Mast Installation1016
Figure # 52 Three Stage Inner Column Assembly1018
Figure # 53 Three Stage Freelift Cylinder Installation1020
Figure # 54 Three Stage Intermediate Column Assembly1022
Figure # 55 Three Stage Outer Column Assembly1024
Figure # 56 Three Stage Single Reach Assembly1026
Figure # 57 Three Stage Single Reach Front Frame Assembly1028
Figure # 58 Three Stage Double Reach Assembly1030
Figure # 59 Three Stage Double Reach Front Frame Assembly1032
Figure # 510 Three Stage Sideshifter Assembly1034
Figure # 511 Three Stage Fork Assembly1036
Figure # 71 TX SCR Electric Schematic – Three Function Control Handle1038
Figure # 72 Battery Lift Interrupt Electrical Schematic Symbols1039
Figure # 73 Battery Lift Interrupt EV-100LX SCR Electrical Schematic1040
Figure # 74 Battery Lift Interrupt Electrical Schematic Symbols1041
Figure # 75 Battery Lift Interrupt Installation1042
Figure # 101 Special Tools and Lubrications1044
Numerical Index1047
Back Cover1068
Front Cover1069
Parts Ordering Instructions1070
General Information1071
Alphabetical Index1072
Figure # 01 Decals and Parts Assembly1076
Figure # 11 Transmission and Steering Installation1078
Figure # 12 Drive Motor Brake Assembly1080
Figure # 13 Transmission Assembly Part # I1082
Figure # 14 Transmission Assembly Part # II1084
Figure # 21 “E” EV-100LX SCR Electrical Schematic1086
Figure # 22 “E” EV-100LX SCR Electrical Schematic Symbols1087
Figure # 23 “EE” EV-100LX SCR Electrical Schematic1088
Figure # 24 “EE” EV-100LX SCR Electrical Schematic Symbols1089
Figure # 25 Wiring Assembly for Cold Storage1090
Figure # 26 Wiring Harness Assembly1092
Figure # 27 Limit Switch Wiring Assembly1094
Figure # 28 Two Stage Mast Cable Assembly1096
Figure # 29 Three Stage Mast Cable Assembly1098
Figure # 210 Single Reach Cable Assembly1100
Figure # 211 Double Reach Cable Assembly1102
Figure # 212 EV-100LX Power Component Wiring1104
Figure # 213 EV-100LX TX & TT SCR Control Panel Assembly1106
Figure # 214 EV-100LX Contactor Panel Assembly & Related Parts for “E” and “EE”1108
Figure # 215 Contactor Panel Assembly1110
Figure # 216 EV-100LX SCR Forward & Rearward Contactor Assembly1112
Figure # 217 EV-100LX SCR 1A Contactor Assembly1114
Figure # 218 Lift Pump Contactor Assembly1116
Figure # 219 EV-100LX SCR Auxiliary Pump Contactor Assembly1118
Figure # 220 Power Connector Assembly1120
Figure # 221 Lift Pump Motor Assembly1122
Figure # 221A Lift Pump Motor Assembly, 36 Volt1124
Figure # 222 Drive Motor Assembly1126
Figure # 223 Auxiliary Pump Motor Assembly1128
Figure # 224 Warning Light Assembly1130
Figure # 225 “E” EV-100LX TT SCR Electrical Schematic1132
Figure # 226 “E” EV-100LX TT SCR Electrical Schematic Symbols1133
Figure # 227 “EE” EV-100LX TT SCR Electrical Schematic1134
Figure # 228 “EE” EV-100LX TT SCR Electrical Schematic Symbols1135
Figure # 229 EV-100LX Dash Display Installation1136
Figure # 230 EV-100LX SCR Electrical Schematic – 3 Function Control Handle1138
Figure # 231 EV-100LX SCR Electrical Schematic Symbols1139
Figure # 230A TX EV-100LX Electrical Schematic – 3 Function Control Handle1140
Figure # 231A EV-100LX SCR Electrical Schematic Symbols1141
Figure # 230B TT EV-100LX Electrical Schematic – 3 Function Control Handle1142
Figure # 231B EV-100LX SCR Electrical Schematic Symbols1143
Figure # 232 Wiring Harness Assembly for 3 Function Control Valve1144
Figure # 31 Hydraulic Schematic1146
Figure # 32 Hydraulic Schematic Symbols1147
Figure # 33 Auxiliary Pump and Reservoir Assembly1148
Figure # 34 Auxiliary Control Valve Assembly1150
Figure # 35 Auxiliary Pump and Motor Assembly1152
Figure # 36 Auxiliary Pump Assembly1154
Figure # 37 Hydraulic Reservoir Assembly1156
Figure # 38 Steering Control Valve Assembly1158
Figure # 39 Steering Control Valve and Hose Assembly1160
Figure # 310 Steering Cylinder Assembly1162
Figure # 311 Two Stage Mast Hydraulic Assembly1164
Figure # 312 Three Stage Mast Hydraulic Assembly1166
Figure # 313 Single Reach, Reach Cylinder Hose Installation1168
Figure # 314 Single Reach Diverter Valve Assembly1170
Figure # 315 Single Reach, Reach Cylinder Assembly1172
Figure # 316 Single Reach, Tilt and Sideshift Hose Installation1174
Figure # 317 Single Reach, Tilt Cylinder Assembly1176
Figure # 318 Double Reach with Tilt and Sideshifter1178
Figure # 319 Double Reach Diverter Valve Assembly1180
Figure # 320 Double Reach, Reach Cylinder Assembly1182
Figure # 321 Double Reach, Tilt Cylinder Assembly1184
Figure # 322 Lift Pump and Reservoir Assembly1186
Figure # 323 Lift Pump Motor Assembly1188
Figure # 324 Lift Pump Assembly1190
Figure # 325 Lift Pump Motor Assembly, 36 Volt1192
Figure # 326 Lift Control Valve Assembly1194
Figure # 327 Two Stage Cylinder and Reservoir Assembly1196
Figure # 328 Two Stage Cylinder Assembly1198
Figure # 329 Three Stage Cylinder and Reservoir Assembly1200
Figure # 330 Three Stage Staging Cylinder Assembly1202
Figure # 331 Three Stage Freelift Cylinder Assembly1204
Figure # 332 Brake Linkage and Cylinder Assembly1206
Figure # 333 Brake Master Cylinder1208
Figure # 334 Drive Motor Brake Cylinder1210
Figure # 335 Idler Wheel Brake Cylinder1212
Figure # 336 Hydraulic Schematic for 3 Function Control Handle1214
Figure # 337 Hydraulic Schematic Symbols1215
Figure # 338 Auxiliary Pump & Reservoir Assy for 3 Function Control Handle1216
Figure # 339 Valve Assembly1218
Figure # 340 Two Stage Mast Hydraulic Assy for 3 Function Control Handle1220
Figure # 341 Three Stage Mast Hydraulic Assy for 3 Function Control Handle1222
Figure # 41 Shielding Assembly1224
Figure # 42 Emergency Disconnect Assembly1226
Figure # 43 Auxiliary Control Assembly1228
Figure # 44 Hand Lift/Lower and Speed Control1230
Figure # 45 Steering Control Assembly1232
Figure # 46 Idler Wheel Installation1234
Figure # 47 Idler Wheel Assembly1236
Figure # 48 Main Frame and Load Wheel Assembly1238
Figure # 49 Single Load Wheel Assembly1240
Figure # 49A Single Load Wheel Assembly1242
Figure # 410 5″ High Articulating Load Wheel Assembly1244
Figure # 410A 5″ High Articulating Load Wheel Assembly1246
Figure # 411 4″ High Articulating Load Wheel Assembly1248
Figure # 411A 4″ High Articulating Load Wheel Assembly1250
Figure # 51 Two Stage Mast Installation1252
Figure # 52 Two Stage Inner Column Assembly1254
Figure # 53 Two Stage Outer Column Assembly1256
Figure # 54 Two Stage Cylinder Installation1258
Figure # 55 Two Stage Single Reach Assembly1260
Figure # 56 Two Stage Single Reach Front Frame Assembly1262
Figure # 57 Two Stage Double Reach Assembly1264
Figure # 58 Two Stage Double Reach Front Frame Assembly1266
Figure # 59 Two Stage Sideshifter Assembly1268
Figure # 510 Two Stage Fork Assembly1270
Figure # 511 Three Stage Mast Installation1272
Figure # 512 Three Stage Inner Column Assembly1274
Figure # 513 Three Stage Freelift Cylinder Installation1276
Figure # 514 Three Stage Intermediate Column Assembly1278
Figure # 515 Three Stage Outer Column Assembly1280
Figure # 516 Three Stage Single Reach Assembly1282
Figure # 517 Three Stage Single Reach Front Frame Assembly1284
Figure # 518 Three Stage Double Reach Assembly1286
Figure # 519 Three Stage Double Reach Front Frame Assembly1288
Figure # 520 Three Stage Sideshifter Assy1290
Figure # 521 Three Stage Fork Assembly1292
Figure # 61 Remote Lift/Lower EV-100 LX SCR Electrical Schematic1294
Figure # 62 Remote Lift/Lower EV-100 LX SCR Electrical Schematic Symbols1295
Figure # 63 Remote Lift/Lower Wiring Harness Assembly1296
Figure # 64 Remote Lift/Lower Three Stage Mast Cable Assembly1298
Figure # 65 Remote Lift/Lower Reach and Platform Cable Assembly1300
Figure # 66 Remote Lift/Lower Power Component Wiring1302
Figure # 67 Remote Lift/Lower Connector Assembly1304
Figure # 68 Remote Lift/Lower Hydraulic Schematic1306
Figure # 69 Remote Lift/Lower Manlift Hydraulic Schematic Symbols1307
Figure # 610 Remote Lift/Lower Hydraulic Diagram1308
Figure # 611 Blocking Remote Lift/Lower Valve Assembly1310
Figure # 612 Remote Lift/Lower Valve Assembly1312
Figure # 613 Remote Lift/Lower Load Backrest Installation1314
Figure # 614 Remote Lift/Lower Contactor Assembly1316
Figure # 71 Battery Lift Interrupt “E” EV-100LX SCR Electrical Schematic1318
Figure # 72 Battery Lift Interrupt “E” EV-100LX SCR Electrical Schematic Symbols1319
Figure # 73 Battery Lift Interrupt “EE” EV-100LX SCR Electrical Schematic1320
Figure # 74 Battery Lift Interrupt “EE” EV-100LX SCR Electrical Schematic Symbols1321
Figure # 75 Battery Lift Interrupt Installation1322
Figure # 101 Special Tools and Lubrications1324
Numerical Index1327
Back Cover1352

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