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MANUFACTURE R'S IFARRANTY

The Manufacruer $amanl$ lo the original user, that each producrofite manulsctue is free from defects in material and factory workmanship

if properly iqstalle4 serviced and operated mder normal conditions

acoding to the Manufactuer's instructioilB.

Manufactuer'e obligation under thia wananty ie linited to correcting

without charge at ite factory sny part or parts therof which ahall be

retuned to its factory or one of ite Authotired Service StaiiorE, trans_

ponation charges prepaid, *ithin one yeu elter being put into selvice

by the original user, and *hich upon examination shall diecloee to the 'Manufactuer'e s*iisfaetion to have bcn originally defective. Conetioq-of euch defets by repair to, or supplying oi replacements for de{ectiYe

pans, shall coneutute fulfllmenr of all obligations o originel u:er.

ThiE wmanty ehall not apply to env ol the Manufactuer's produ6ls

*hich mut be replaced bwauae of nornal wear, which have been subject

to misuse, negligence ot acaident or which shall have been repaired or

altered outride oi the Manulactuer'e factory urless authorized by the

M an ufac ruer.

.Manu{mtuer aball not be tiable for loea, damsge or expense directly or

indirrcdy iom the use of its Foduct or iom any other cause.

The above wenanty euperredee and ie in lieu of all other wananties,

expreseeil or implied, md of ell otLer liabilities or obligatione on part ofMaaulaeuer. No person, ageut or dealer is authorized to give any

wmantiee on Lehalf of the Manufactuer tror td assume fo. the Manu'factuer any other liability in connectioo with sn} of it6 products unlesp

made iu witing and signed by an offcer ol the Manufactuer.

CORPORATIOT25tE uNtvERgrtY avENuE s.E. ' MINNEAPoLIS' MlNNEsorA 55414

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Do not attempt to overhaul valves or drive mo-tors in your plant. Send these cofnponents toauthorized dealer for repair or exchange themfor rebuilt units.

The lift cylinder has a vee packing which maybe tightened to stop any leakage. There is abrass spanner nut at the top of the cylinderwhich forces the packing tighter around the

. ram. Use only enough pressure to stop leaks.Undue tightening will cause excessive wear onthe ram. Change hydraulic oil every 3,000 hoursor annually, whichever comes first.

LUBRICATION

The steering shaft his two U-joints and twobushing housings which should be greasedevery 100 hours. At the same intervals greasethe mast channels and lift sprockets. In verydirty conditions grease oftener for best results.Any good chassis grease may be used. , iDrive wheel and rear wheel bearings shoul&berepacked every 3,000 hours or annually, ry'hichever comes first.For engine service please refer to page 30 ofthe Onan Instruction Manual for periodicmaintenance.

GENERALPlay in Steering. Remove the cover plate onrear step. Loosen 3 bolts holding clampingflange down on adjustment sleeve. Turn adjust-ment sleeve until pinion bottoms out. Back upslightly to provide clearance and retightenbolts.

Side Play in Mast. Mast hold downs are drilledoff center to provide an eccentric. Loosen boltin motor component. Turn hold down until itstops, then tighten bolts.

Basket or Fork Level. Two adjustment bolts onend of chain can either be tightened or looseneduntil the basket sets level.

Two Speed Valve Linkage. The shift rod mustbe shortened when the fork lift does not go intolorv gear. This could be a result of the shift rodstre.tching or Wear on the clevis pin.

Onan Engine Service and Parts. Points, plugs,and condenser may be obtained from NAMCO.For repair and all other parts, contact nearestOnan Sales and Service Dealer.NOTE: FOR FOUNDRY OPERATION. AIt

.\ lubrication and Hydraulic instructions should be' followed twice as often as normal conditions.

HYDRAULIC SYSTEM

Hydraulic oil systems must be kept clean foreffective service life. Most ineffecient systemsare the direct result of dirt and other foreignelements. The hydraulic oil filter should bechanged after the first 50 hours of operation.Filter changes should be maintained every 250hours for maximum life.

A daily check should be made to see that thehydraulic reservoir is completely full of oil.Cavitation or inefficiency will result from a lowreservoir.

There are four adjustable relief valves in themain control valve. The main relief is locatedat the top right side. It should open at 1250 psi.

CAUTION: DAMAGE TO THE SYSTEM WILLRESULT IF ABNORMALLY HIGH PRES-SURES ARE USEP/To adjust the main relief, remove cover screwand use a small screw driver. Turn adjustmentscrew clockwise to increase pressure. Thisshould only be performed when the fork lift haslost power and the engine is running correctly.

Cylinder port reliefs are located near the outletports. There is one for the lift mechanism andtwo for the tilt. These reliefs should be adjustedonly if it will not pick up the rated load.

CAUTION: IF CYLINDER PORT RELIEFSARE SET TOO HIGH, AN UNSAFE FORKLIFT MAY RESULT IN OPERATOR INJURY.

AII Hydraulic hoses on this unit have reusablecouplings. Remove the hose from the truckby unscrewing the coupJ.ing from the adapter.Do not remove the adapter from its component,i.e. pump, rrrotor, valve, etc., unless the com-ponent is being replaced. The coupling is &adein two pieces which are screwed togdtherclamping the hose in position. To remove thecoupling from the hose, simply unscrew thetwo coupling pieces.

Reassembling is done in the following manner.First, screw the outer piece on the hose untilit stops, then back up t/+ turn. Put a smallamount of 90 weight grease on the taperedin_ner piece and screw the two pieces together.Blow out the hose assembly so no dirt will beintroduced into the system.CAUTION: EXERCISE CARE TO KEEP ALLDIRT OUT, COVER ALL OPEN CONNEC-TIONS DURING REPAIR. WIPE CONNEC-TIONS CLEAN BEFORE REASSEMBLY

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ItlA.T\TEETGENERAL SECTION

The right and left sides of the Fork Lift Truck, as referred to in the text of the service manua], will be viewedwhile Jtanding on the machine in the operating position. The steering tiller handle is on the left side and hy-draulic control handles are on the right side.

STEERING PINION ADJUSTMENT:

1.0 The steering pinion is located on the rear platform -underneath -the hinged c_over. Loosen the t h r e epinion take up holddown bolts. Rotate pinion take gO sleeve-9ntil the pinion and_the steering-gears are inmesh and not-touching tooth crowns. The steering tiller should be in the forward-position when-the'rearwheel is in a straight forward running position. Back off pinion take up sleeve slightly to get smooth turningaction from lock [o lock. Tighten the three hold down bolts.

Pinion Take Up

Hold Down Bolts

Rotate PinionTake Up Sleeve

FUEL FILTER

1.1 The fuel filter is a replacement type located to the left of the_hydraulic pump mount. Remove nuts orclamps, whichever applies t6 your lift fruck, to remove filter cartridge. Replace with new element every 3000

hours or annually. Use AC. No. GF-11-4ONAN ENGINE

1.2 Adjustments for the Onan Engine; i.e., plug gap, p_oi!t_gap, timing etc., can be found in the Onan Op-erators Minual or Onan Service Manual for the Model CCK Engine.

1.3 To remove the engine from the lift truck for major work, use the following-procedure. Remove clipslotai"g tfr" throttle and Ehoke cables and disconnect wire ends. Remove starter cable from terminal at thestarterl GAUTIoN: DIScoNNEcT coIL wIRE, BATTERY GRoUND CABLE, AryD GETERATORiVlIiES,

-vlanrlxC EACH ONE FOR REASSEMBLY. Disconnect the fuel line at the fuel filter inletto".t"d io the left of the carburetor. Remove the two speed valve linkage. IJnscrew the two bolts at*each endo] ttt" muffler manifold and remove the manifold. Loosen lower exhaust hose clamp and remove muffler mani-fold and hose as a unit. Remove the 'four bolts holding the pump mount to the engine. , Loosen the."f r"""* on the engine side of the chain coupler and remove ,th-e pump moqP! assem-bly from the

""gi"L. R"*o.r" the thrle bolts holding, the engine_ to the chassis. T\vo bolts are located below the starter and

""E Uott by the front left corner. Pull the righi side of the engine forward so the air duct will clear the frame.

Lift engine up and remove out the right side'

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ilrlA.IIIEET1.4 To install the engine use the reverse procedure outlined in Paragraph 1.3.

1.5 Throttle settings should be made at the end of the cable which hooks to the governor spring. This spring;hould have no tension when the engine is not running. The throttle wire should move approximately 1/16"before the spring starts to have tension. Tleis setting will run the engine at 2400 rpm when the throttle is open.

CAUTION: DO NOT RUN ENGINE ABOVE 24OO RPM AS IT WILL D A M A G E THE HYDRAULICPUMP.

1.6 Insert choke wire into the arm at the carburetor. Make sure choke button on hood is pushed in andmove choke cable at the carburetor until butterfly valve is wide open. Hold in that position and replace clipon choke mount.

LIFT CHAINL.7 Each of the two lift chains may be loosened or tightened separately. This is done because one chain maystretch more than the other after a number of working hours. Eaeh chain has an adjustment bolt iocated atthe end which may be tightened or loosened until the carriage sets level and both chains are carrying equalweight. Run the carriage to the top with the mast in a vertical position. There should be approximately t/rtt 6"-tween the earriage support bars and the inner mast.

1.8 CAUTION: NO CLEARANCE BETWEEN THE INNER MAST AND THE CARRIAGE WILL PUTUNDUE PRESSURES ON TTIE LIFT CHAINS CAUSING THEM TO BREAK.

PARKING BRAKE1.9 To adjust the parking brake, the fork truck should be blocked up on the right side. This gives easyrccess to the brake mechanism located underneath the right fender. Loosen the two hold down bolts whichhold the brake in position. Pull the control knob, on the hood top, to the engaged position. Slide the brakemeehanism assembly toward the wheel until the pawl firmly engages the gear. Snug the holding bolts and pushcontrol knob down to disengage the brake. Turn the wheel by hand to make sure the pawl and gear are clearof each other. If any binding occurs, tap brake mechanism slightly to the rear until free. Tighten hold downbolts.

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hIAII,IETMAST LOCKS

1.10 The mast is held in position by a mast lock on each side of the truck. These locks should be checkedperiodically to make sure-they havi not loosened. The mast will have sideways movement if they are loose'

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1.11 The mast lock bolt is located insidethe drive motor comparfunent just above each drive motor mount.Loosen each bolt. Make sure the mast is seating properly on axle housing and tighten the bolt letting the mastmounting plate hold the eccentric loek from turning, This method of tightening insures the mast lock fromloosening due to pressure from the mast.

DRIVE AXLES

7.72 The drive axle is full floating. It is a hardened steel sleeve splined at both ends to mate with the splineson the hydraulic drive motors and drive plates. Removal of the six bofts holding the drive plate to_the- wheelallows tlie axle plate to be disassembled. The drive axle, now exposed, may be taken out. Check all splines tosee if they are in good condition. Replace badly worn drive axles. Apply a small amount of wheel bearinggrease to the splines when reassembling.

1.13 CAUTION: CHECK DRIVE AXLES AND DRIVE PLATES IF YOUR FORK LIF"I DOES NOT OP-ERATE IN LOW RANGE, BUT DOES OPERATE IN HIGH RANGE. EXCESSIVE DAMAGE MAY RE-SULT WHEN TRUCK IS OPERATING ON ONE DRIVE MOTOR.

I.14 Excessive axle wear may be caused by the motor relief valve being set too high. This relief shouldbe set at 1250 psi maximum. Refer to hydraulics section, paragraph 2.24 for detailed pressure setting instruc-tions.

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hlAIilECTHYDR,AULIC SECTION

2.7 CAUTION: EXERCISE CARE, WHEN WORKING ON THE HYDRAULIC SYSTEM, TO K E E PALL DIRT OUT. RECOMMENDED PRACTICE IS TO STEAM CLEAN THE FORK TRUCK BEFOREDISASSEMBLING ANY COMPONENTS. COVER ALL OPEN CONNECTIONS DURING REPAIR ANDWIPE ALL CONNECTIONS CLEAN BEFORE REASSEMBLY.

HYDRAULIC PUMP

2.2 The servicing of the hydraulic pump should be limited to removal and replacement. It is not recom-mended that the owner or dealer overhaul the pump as special machines are needed to obtain the correctclearances in the gerotor mechanism.

2.3 Use a wrench to hold the adapter at the pump and remove the hose from the adapter by turning thehose swivel nut. Remove both the suclion and discharge hoses from the pump connections. Loosen the setscrew on the chain coupler on the pump shaft side. There are {our nuts on the inside qt tb" pump mount cast-ing holding the pump.

^The pu-p hay-be removed after the nuts have been taken off. Remove the adaptersfrJm the pump houslng whbn i[ is to be replaced with a, new pu_mp. Use teflon tape ol permatex on theadapter tht"rdr if the fump you are using has pipe threads. Pipe thread pumps are painted red for identifica-tion. Replace "O" rings on yellow pump adapters.

2.4 CAUTION: DO NOT EXERT UNDUE FORCE WHEN PUTTING THE ADAPTERS IN AS THEPUMP HOUSING WILL CRACK. TIIE USE OF TEFLON TAPE ALLOWS THE ADAPTER TO GO AFULL THREAD DEEPER IF THE SAME TORQUE IS APPLIED THAT NORMALLY IS USED TO SEATBARE PIPE THREADS.

TWO-SPEED VALVE CONTROL

2.5 The two-speed valve controls the flow of oil either series or parallel to the drive motors. Refer to ServiceBulletin No. 14 for schematic diagram.

2.6 CAUTION: THE TWO-SPEED VALVE USES ONLY TWO OF THE THREE AVAILABLE POSI-TIONS. Use only the positions of the valve spool when it is completel)' out and half the way in. The traveldistance will be 7a".

Pump Shaft Setscrew

filA.I\'EET2.7 Stretching or bending of the shift rod or wear in the clevis pin could prevent the shifting of the two-speed valve spool to the correct location. Remove the clevis pin and loosen the clevis locknut. Turn clevis aturn or two, replace and check for proper valve positions as noted in paragraph 2.6.

SUCTION FILTER2.8 The suction filter is mounted directly to and above the pump. Clean screen filter in solvent and blowout with an air gun. This filter should be cleaned every time the hydraulic oil is changed. The recommendedtime to change oil is every 3000 hours. At the base of the filter case is a drain plug which has to be removedto drain the filter case. Wash filter case with solvent and wipe dry to remove all sediment.

2.5 CAUTION: BE SURE COVER GASKET AND HOLD DOWN BOLT SEAL IS PROPERLY SEAT-ED. AIR LEAKS ON THE SUCTION SIDE WILL CAUSE CAVITATION OF THE PUMP. CAVITATIONRESULTS IN NOISY AND SLUGGISH OPERATION.ITYDRAULIC OIL FILTER2.10 There is a ten micron oil filter in the return to hydraulic reservoir line. This filter is located on the leftside of the truck and is the throw away canister type. IJse a metal trough to divert the oil to the outside of thetruck. The filter unscrews in a counter-clockwise direction. It should be changed after the first 50 hours ofoperation and every 250 hours thereafter for maximum protection of the hydraulic pump and motors.HYDRAULIC OIL2JI A daily check should be made to see that the reservoir is completely full of oil. Cavitation and ineffi-ciency will result from a low oil level.

2.12 To change oil, run the right side of the truck to the edge of a loading dock or block the truck upsufficiently high to get a drain pan underneath. The hydraulic oil reservoir holds 11 gallons of oil. There is areservoir drain located underneath the right fender toward the rear. Replace drain plug and refill with TypeA automatic transmission fluid or a high grade of oxidation and rust inhibited hydraulic oi1 SSU grade 150 @100" F. Change hydraulic oil every 3000 hours.

2.13 CAUTION; DONOT USEMOTOROIL. EXCESS FOAMING AND HEAT WILL REDUCE THEEFFICIENCY OF THE SYSTEM.MAIN RELIEF VALVE

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LowerPressure

RaisePressure

REV

2.14 The main relief valve is located on the top of the main control valve, to the right of--the right handcontrol lever. Access to the main relief valve is through the right hand slot. Remove top hex cap nut which isthe smallest hex nut showing. Underneath the hex cap is a slotted serew. To raise the pressure turn theslotted screw clockwise. The main relief should open at 7250 psi. Insert test gauge in the front drive hose as-sembly. Push control lever in forward position with engine running. Test gauge will show the pressure themain relief is opening.

IIA,}IEET2.15 CAUTION: DAMAGE TO THE SYSTEM \MILL RESULT IF PRESSURES HIGHER THAN 1250PSI ARE USED.

2.16 All precautions have been taken to keep the hydraulic system clean. However, there 5_ti,l1 ,remains thepossibility of di"t entering the system. Dirt can get into the small ports in the malq relief and hold the valvein an open position. This would result in very poor performance characteristics of all functions or no operationof all functions.

2.I7 The main relief valve may be removed by unscrewing the large hex nut at the main valve casting. Thisremoves the body and valving. Clamp the large hex in a bench vise an<i use a screwdriver to remove theadjusting screw inside the valve body. Tip the valve body over so the spring and poppet_ vslvs frall out. Washalipiecei with solvent anC air dry. Checkinside the .,'alve body and around the ;loppet valve for dirt and metalchips which could hold the valve open. Wipe pieces off and reassemble. Reset the pressure after installing inthe fork truck.

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LIFT RELIEF VALVE

2.18 The lifting section of the valve is in the center section with one hose leading from it to the cylinder.Just below the hose port is the lift relief valve. IJnscrew the thin hex cover nut. To set the port reliref,_use a7e" hex wrench and-iasert it in the center of the relief. To raise the pressure turn the screw clockwise.Replace the hex cover nut after the pressure has been set. Insert gau_ge in lift cylinder line to find pressureset on the lift relief valve. Lift control handle must be in the raised position with the engine running.

2,I9 CAUTION: IF CYLINDER PORT RELIEF IS SET TOO HIGH, AN UNSAFE FORK LIFT TRUCKMAY RESULT IN OPERATOR INJURY.

2.20 It may be necessary to change the main relief valve to a higher pressure along with the lift relief_valvewhen converiing a mo<iei 1S-tS to J ZO-fS for greater capacity. The best sequence is to set the lift relief higle-rthan necessary ind set the rnain relief to carry the load. Reset the lift relief after the main relief is set. Liftvalve settings are as follows: Model 15-15, 1100 psi; Model 20-15, 1200 psi.

2.21 Dirty or contaminated oil can cause a varnish to form on the piston and bore of the lift relief valve.This varnish or particles of dirt renders it inoperative. Remove cylinder port relief from truck. A correctoperating piston should be held in the body by a snap ring and will move freely whe! oper,ated by hand. Pusht6e piston-away from the snap ring and remove the snap ring. Tapping the valve body wil! rele_ase the pistonso ii can be dlsassembled. Remove the adjusting screw, spring, and poppet by turning the adjusting screwcounterclockwise. Wash all parts in solvent and air dry. Check inside of valve body and around the popPetvalve for dirt and metal chips which could hold the valve open. Wipe pieces dry and reassemble. Reset thepressure after installing in the fork truck. (Diagram on next page)

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TILT RELIEF VALVES

2.22 The tilt reliefs are preset to higher pressures than necessary to operate the tilt cylinder for load condi-tions. Its primary function is to relieve the pressures created by the restricting orifice which slows down thetilt speed. The tilt reliefs could be raised, if necessary, by the following procedure. The caps by the port outletsshould be removed. A spring and poppet valve will come out as the cap is removed. Place a shim washer be-tween the spring and the cap to raise the pressure. In the event the O-Ring seal should drop out, put somegrease on tlie seal and replacl in the valve. The grease will hold the seal from falling out during reassembly.ihese reliefs should open-at 800 psi. Insert test gauge in top port to check the relief in the top of the valve.Use the lower port for the relief located on the underside.

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2.23 CAUTION: THE TILT RELIEF WILL NOT FUNCTION PROPERLY IF THE O-RING SEAL ISNOT PROPERLY SEATED OR IF IT HAS BEEN DAMAGED SLIGHTLY.

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MOTOR RELIEF VALVE

2.24 A rnotor reli,ef'valve is located to the left of the two speed control valve and directly connected to it.Remove the hex cover nut at the forward, top end. A slotted screw is now exposed which may be turned clock-wise to raise the pressure or turned counter-clockwise to lower the pressure. To test the relief insert test gaugebetween the motor relief valve and the drive motor. Use the high range anil control lever in forward position.This test method puts a pressure between the drive motors and the motor relief must function at its pressuresetting. Pressure should be set at 1100 psi. (Diagram on next page)

hlA.I\'IEET qHex Gover Nut

Slotted Adiustment Screw

HYDRAULIC HOSESREMOVAL

2.25 Remove the hose from the fork lift by unscrewing the hose coupling from the adapter. Do not removethe adapter from its component, i. e., pump, motor valve, and etc., unless the component is being replaced.

COUPLINGS

2.26 AII the hydraulic hoses on this unit have reuseable couplings. The coupling is made in two pieces whichare screwed together clamping the hose between them. Remove the inner piece by clamping the outer piecein a vise and unscrewing the inner piece. The outer piece has a left hand thread which screws on the hose. Toremove the outer coupling from the hose, turn it in a clockwise direction.

CouplingOuter Piece

Gouplinglnner Piece

2.27 Reassembling is done in the following manner. First screw the outer piece on the hose, in a counter-clockwise direction, until it seats firmly against the hose. Back the coupling off L/+ turn. Place a small amountof grease 90 weight, on the tapered inner piece and screw the two pieces together. The outer and inner pieceproperly installed will seat together. Blow out the inside of the hose so no dirt will be iptroduced into thesvstem.

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hl'\hIEETLIFT CYLINDER

2.28 The lift cylinder has a vee or chevron packing which mey be tightened to stop any leakage. Tbere is abrass spannet rrut to the top of the outer tube, which forces tbe vee-paeking-tighter around the ram. Turn thespatrnei nut in a clockwise-direction to tighten the packing. Use only enough pressure to stop the leakage asu^ttdue tightening will cause excessive wear on the ram and packing'

2.29 CAUTION: INSPECT FULL LENGTH OF RAM FOR NICKS OR SCRATCHES WHICH MAY CUTPACKING.

HYDRAULIC DRIVE MOTORS

2.30 To remove disconnect the hose couplings from the adapters on the drive motors. Raise the carriageapproximately four feet off the floor andblock it up_sr someone_do_esn't accidentally 1et it do-wn. Rem_ove theflange bolt uiing an open end wrench through the slot provided. Remove the two-clamp bolts and^e_lamphold-ing the reaiof thddrive motor. Clamp must be rep'[aced in the same position on_the same lower half. Wipeclean fiefore reassembly. lfnscrew the back flange bolt and remove drive motor. Remove the adapters fromthe drive motor, noting position, and replace in the new unit to be installed.

2.gl The flange socket in the axle housing should be wiped clean to insure the prop_er seating of the-irivemotor. Install t[e motor shaft into the splined axle and fit the guide flange into the socket. Put the two flangebolts in. Snug each one up before the finll tightening tr insure proper seating. Put clamp on lear of th-e drivemotor and snug bolts up. Replace the hoses on the proper adapters. Block up the tires so-they can _be- run.With the truck-in low ringe ind throttle blocked in running position, start torquing down the clamp bolts. Aslight chattering can be heard as the motors are being run. Start with 10 foot-po-unds of torque,- lYnningap"proximately 5 minutes, and increase the torque in S-toot-pound increments until the recommended 3O-foot-pounds of toryue is reached. Run the motors 5 to 10 minutes between each tightening.

2.32 CAUTION: DO NOT TIGHTEN CLAMP BOLTS IN EXCESS OF 30 FOOT-POUNDS OR MOTORWILL SEIZE. IF MOTOR SHOULD SEIZE DURING RUN IN, LOOSEN CLAMP BOLTS AND REPEATRUN IN SEQUENCE

Upper Glamp Half

Lower Glamp Half

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IIA,}IEETLUBR,ICATION SECTION

LOCATION OF GREASE ZERKS

3.0 Grease the fork lift truck every 20 hours. This interval should be lessened to 10 hours if the fork lift isoperated in a dirty environment. Be sure to grease all six of the zerks. The chain sheave zerks are located inthe ends of the bolts holding the sheaves in place. The steering housing and upper steering joint are locatedin the upper left side of the fork truck hood. The steering cover, located in the center of rear platform, mustbe raised to grease the lower steering U-joint and the pinion.

Ghain Sheave

Steering Housing

Upper Steering U-Joint

l-ower Steering U-Joint

Pinion

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lr^a,DlEErFRONT WHEEL BEARINGS

3.1 Repack the wheel bearings every 1-000 hours. Six bolts must be removed from the driv_e plate locatedon the oufside of the wheel. Reriove diive plate and set aside. Bend the engaged tabs of the lockwasher out ofthe slots of the locknut. Block up the truck and remove the locknut. The wheel and tire assembly can now betaken off. Wash bearings in a de-greasing solvent, repack with heavy duty wheel bearing grease and replace ontruck. Tighten locknut snugly and lock with tab of lockwasher.

REAR \MHEEL BEARINGS

3.2 Repack wheel and pivot bearings every 1000 hours.

3.3 Raise the rear of the truck up approximately one foot, placing blocks underneath where the rear plat-lorm joints the main frame. Pry off the cap, in the center_of_the rear platfo-rm-top, using__a larg-e screwdriver.Remove the now exposed cottei and nut. fhe

"ear wheel fork assembly will drop out. Use a long punch to

drive out the lower pivot bearing and seal.

3.4 Loosen the three pinion adjustment hold down bolts. Rotate adjustment sleeve until the pinion shaft isnearest the front of the truck. This will make the reassembling easier.

3.5 Remove the axle nut from the rear wheel fork assembly. Note the flange side of the wheel has a longerspacer than the other side. Remove wheel by pulling axle out. Take the seals out to remove the bearings.

3.6 Wash the four bearing cones in a degreasing solvent, repack with wheel bearing grease, -and install byreversing the above procedu-re leaving the pinion idjustment until iast. Refer to paragraph 1.0 for adjustmentprocedure.

MAST CHANNELS

31 The mast channels should be lightly greased every 1000 hours. This interval should be lessened toevr:ry 500 hours if the fork truck is op""rt"d in a dirty envirott-ent. The old grease should be washed off beforeregreasing. Use a good grade of chassis grease.

3.8 CAUTION: GREASING EXCESSIVELY CAUSES DIRT TO CLING MAKING THE CHANNELSSTICK. IF CHANNELS BIND AND MAST WILL NOT RETRACT, DISASSEMBLE AND THOROUGH-LY CLEAN AND RELUBRICATE AFTER ASSEMBLY. THE CARRIAGE LOAD AND SIDE THRUSTROLLERS ARE SEALED NEEDLE BEARINGS AND CANNOT BE LUBRICATED. IF ONE OR MORE

FAILS TO TURN FREELY, REMOVE AND REPLACE WITH A NEW ROLLER ASSEMBLY. REFER

TO PARTS BOOK FOR BEARING NUMBER.

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hlA.IilEETPROPANE FUEL SYSTEM SECTION

4.0 The NAMCO L.P.G. fueled truck is equipped at the factory with high compression cylinder heads anda 14 lb. VAPOR WITHDRAWAL cylinder installed in the engine compartment at the left front corner.

4.1 CAUTION: DO NOT USE LIQUID WITHDRAWAL CYLINDERS ON NAMCO OR COMPLETEDESTRUCTION OF THE REGULATORS WILL RESULT.

4,2 ELECTRICAL FUEL CONTROL DIAGRAM

lgnitionTerminal

Stal{Terminal

lgnition Switch

NormallyClosed

Oil PressureSwitch

Solenoid LockoffValve

SOLENOID LOCKOFF

4.3 General Control Cat. No. PVIC1154. This solenoid valve automatically stops flow of gas from cylinderto-primary regulator- when ignition switch is off or when engjne stops or when engine oil pressure drops below5 lbs. pressure. If valve does not function or leaks, check coil for continuity and-for vol-tage when Jtarter isengaged. Disassemble and clean solenoid core, valve stem, and seat.

PRIMARY REGULATOR

4.4 Pressur_e range 15ffi in1el, _8 oz. ou_tlet. Outlel pressure should not exceed 8 oz. If regulator fails topass gas or_leaks, disassemble and clean needle and seat.-Reset outlet pressure to 8 oz. or L0"-water columnafter assembly. Regulating screw is located under the cap on top of re-gulator diaphragm bonnet.

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NAhIEETSECONDARY REGULATOR

4.5 The only adjustment on the Model "KN" is the lock-ofJ or id.le adjustment located just above the fuelinlet. This will normally be set at the factory to lock-o{f or shut off the flow of gas at an inlet pressure of 4ounces, unLess a different inlet pressure has been specified.'This_ adjustment should be checked after installa-tion with the gas inlet pressure to be used. Open the solenoid and temporarily plug one balance opening andblow into the bther balance opening so as to open the seat and allow fuel to f1ow. Remove the fuel outlet hoseand put a soap bubble over the hose nipple. Turn the adjusting screw out or counterclockwise until the fuelseeps through ilowly making the soap bubble grow larger. Turn the adjqsting screw in slowly until the soapbubble will hold. Check this lock off point several times by repeating the above process of opening the regu-lator and using the soap bubble to determine if fuel is seeping through. After the lock off point has been de-termined for the inlet gas pressure used, the screw should never be turned out or counterclockwise. The ad-justing screw may be turned in from this point to lean and set the idle mixture. Do not use this screw to set themain load mixture, high speed idle mixture or idle speed.

4.6 NOTE: SMALL SCREENED VENT OPENING AT SIDE OF HOUSING MUST BE CLEAN ANDOPEN TO PERMIT PROPER OPERATION OF REGULATOR.

4.7 NOTE: BOTH PRIMARY AND SECONDARY REGULATORS MAY BEST BE ADJUSTED ONTHE BENCH WITH AIR PRESSURE BEFORE REINSTALLING IN THE NAMCO TRUCK.

CARBURETOR

4.8 The LPG carburetor is a standard ONAN unit furnished with the engine and parts may be purchasedfrom NAMCO or from your local ONAN service staticn.

HIGH SPEED JET

4.9 The adjusting screw is located on the front of the carburetor body just below the fuel inlet connection.It is the large knurled screw facing the front of the lift truck. Turn screw counter-clockwise about two fullturns and start engine. Run engine five minutes to warm up. Open throttle control to full speed and slowlyturn screw clockwise until engine speed reduces. Turn screw counter-clockwise until engine resumes fullspeed. Push tilt lever forward to load engine and readjust screw until maxirnum speed is obtained. NOTE:ALWAYS SET ADJUSTMENT ON LEAN SIDE FOR MAXIMUM FUEL ECONOMY.

IDLE JE"T

4.10 The adjusting screw is located on the left side of the carburetor body just-below the fuel inlet con-nection. It is a small knurled screw. With engine idling, turn screw clockwise until speed reduces. Back screwout until idling speed increases to maximum" Load engine with tilt control and readjust to prevent enginestalling. If stalling persists, increase idling speed slightly and readjust. NOTE: THE GOVERNOR OR SPEEDCONTROL SPRING MUST BE TIGHT ENOUGH TO ACTUATE GOVERNOR WIIEN LOAD IS APPLI-ED TO ENGINE BUT LOOSE ENOUGH TO RETURN ENGINE TO NORMAL IDLE SPEED WHEN UN-LOADED. NORMAL UNLOADED IDLE SPEED IS 8OO TO 9OO RPM.

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Trouble

1. Motionless in I o wrange, high range okay.

2. Motionless or sluggishin all functions; lowand high range, lift andtilt.

3. Truck is sluggish inhigh or low but goodin one or the other.

4. Lift function does notoperate. Tilt, high andlow motion works.

5. Lift creeps downward,will not maintain loadheight.

N,l.T\'EETTROUBLE SHOOTING GUIDE

Probable Cause

Drive axle spindles worn or shear-ed off.

Drive plate spindles worn or shear-ed off.

Shift rod stretched or pins worn.

Drive motor worn or damaged in-ternally.

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Key in pn-p $h.itr coupler shear-ed.

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":'Chain couplbr worn.Suction filter'dirty or leaking air.

Hydraulic oil reservoir low.

Pilot operated main relief valve isbeing held open by foreign matter.Main relief valve pressure set toolow.Engine lacks power.

Badly worn pump.

Two speed linkage out of adjust-ment.

Drive motor hoses on wrong con-nections.

Dirty cylinder port relief valve orbroken spring.

Engine lacks power.

Broken "O" Ring at the relief valveseat.

Dirty cylinder port relief valve orbroken spring.

Relief pressure set too low.

Badly worn valve, spool bypassing.

Remedy

Replace axle.Refer to para. 1.12

Replace drive plate.Refer to Para. 1.12

Adjust linkage or replace pins.Refer to para.2.7

.Replace drive motor.Refer to para. 2.30.

Replace key.

Replace chain and sprockets.Clean filter and reseal gaskets. Replacegaskets if necessary.Refer to para. 2.8.

Fill to full level on dipstick with forksfully lowered.

Remove main relief and clean.Refer to para. 2.I4.Reset pressure to 1250 psi.Refer to para. 2.74.

Clean carbon from heads. Reset timing,carburetor, throttle linkage. Overhaulengine if necessary. Check engine com-pression.Refer to Onan engine manual.

Replace pump.Refer to para.2.2.

Readjust linkage to insure proper ac-tuation.Refer to para. 2.7.

Plumb correctly, refer to hydraulicspage in parts book.

Relief valve on underside of centerstack of the main valve should be re-moi'ed and cleaned in solvent.Refer to para. 2.18.

Clean carbon from heads, reset timing,carburetor, or throttle linkage.Refer to ONAN Engine Manual.

Replace, use No. 1-0 "O" ring.

Relief valve on underside of center sec-tion of the main control valve should beremoved and washed with solvent.Refer to para. 2.18.

Increase tension using a 7/e" A1lenwrench to turn clockwise.Refer to para. 2.18.

Replace valve section.

Trouble

6. Tilt creeps forward,will not hold mast invertical position.

7. Truck moves jerky butengine is runningsmoothly, pump has ahigh pitched noise.

8. Breaking axles.

9. Hoses break.

10. Oil leaks in hydrauliclines.

11. Engine is sluggish orinoperative.

12. Throttle does not re-turn to idle position.

13. Engine does not re-spond to throttle.

14. Parking brake does notwork.

h|AI'EETProbable Cause

Broken or worn "O" ring at therelief valve seat.

Dirty cylinder port relief.

Relief pressure set too low.

Badly worn valve, spool bypassing.

Pump cavitating from air being in-troduced into suction line orfilter.

Low hydraulic oil level in reser-voir.

Main relief pressure set too high.

Motor cross over relief at the twospeed set too high.

Pressures set too high.

Worn hose.

Damaged "O" Rings on adapters.

Leaking coupling at hose fitting.

Worn hose.

Check Onan Service Manual.

Carbon in heads.

Throttle spring at fire waIl dis-connected or broken.

Throttle wire broken or discon-nected.

Adjustment at throttle arm on en-gine set too loose, will not tightenspring hooked to end of cable.

Stretched throttle spring on theengine.

Throttle wire casing clamps loose.

Cable control wire broken.

Cable control wire disconnected.Pawl not engaging toothed gear.

Toothed gear or pawl badly worn.

Pawl guide out of adjustment.

Remedy

Replace, use No. 10 "O" Ring.Refer to para. 2.22.

Remove cylinder port relief from un-derside of the left end section in themain control valve, and clean.Refer to para. 2.22.

Add shim in cap.Refer to para. 2.22.

Replace valve section.

Check all connections for proper seat-ing. Suction filter cover or hold downbolt seal leaking air.Refer to para. 2.8.

Fill to full level on dipstick with mastfully collapsed.

Reset pressure to 1250 psi.Refer to para. 2.\4.

Reset pressure to 1100 psi.Refer to para. 2.24.

Reset main and cross over reliefs.Refer to para. 2.\4-2.24.

Replace hose.

Replace.

Remove coupling, cut approximately 1"off hose and replace.Refer to para. 2.26.

Replace hose.

Tune Engine.

Remove and clean.

Replace or reinstall.Refer to para. 1.5.

Connect or replace.

Readjust so engine runs at 2400 RPM.Refer to para. 1.5.

Readjust or replace.Refer to para. 1.5.

Tighten.

Replace.

Reinstall.Readjust.Refer to para. 1.9.

Replace.Refer to para. 1.9.

Readjust.

N'rIilErIL

! Trouble Probable Cause Remedy

15. Hydraulic cylinders Chevron packing in iift cylinder Tighten.

Packing or "O" rings worn. Replace.

16. Steering loose, exces- Pinion and steering gear not mesh-sive play. ing properly.

17. Steeri:rg hard.

18. Carriage develops side One lift ehain too tight.play.

Natural wear.

Dry slides.

Dirty channels.

Carriage twisting.

Lift cylinder binding.

Mast locks loose.

Loose steering gear.

Worn U-Joints.Worn pinion or steering gear. Replace.

Dry bearings and U-Joints. Lubricate.

Pinion meshing to tightiy with Readjust.steering gear. Refer to para. 1.0.

Broken bearing in adjustment Replace.sleeve.

Steering shaft rubbing frame. Readjust.

Adjust.Refer to para. 1.0.

Remove rear wheel fork and tightenbolts holding gear.Refer to para. 3.3.

Replace.

Adjust for same tension.Refer to para. 1.7.

Remove carriage and shim side thrustrollers.Lubricate.Clean.Adjust lift chains.Refer to para. 1.7.

Loosen packing nut.Refer to para. 2.28.

Tighten.

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19. Mast sticks.

Broken or loose rollers. Tighten or replace.

Inner mast bent. Remove and straighten.

20. Mast has side play. Mast locks loose. Tighten.

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No. Req'd.100,591100,592100,593100,594100,185100,190100,184100,180

Control CableThimbleCasing ClipSpringBrake LinkBrake ArmBrake ChannelRear LinkyB" xlt' N.C. Flat HeadStove BoltyB" x Itt N.C. Hex HeadScrew

/g" Lock Washer3fl'Hex Nut5f 16" Lock Washer5/16" Hex Nutr

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10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

2t.22.

23.

24.

25.

100,595

100,752

100,597

100,598

100,599

100,600

100,601

100,603

101,397

100,602

100,618

100,706

100,604

100,608

100,609

100,753

100,63 1

100,617

100,616

100,615

100,614

100,610

100,611

100,612

100,639

100,613

100,842

100,82I

101,398

104,167

Oil Gauge

Electric Oil Gauge

Hour MeterAmmeter Gauge

Gasoline Gauge

Starter Solenoid

Voltage Regulator

Ignition Switch

Ignition Switch,2 Position Off-On

Battery, Group 2SM

Gasoline Sending UnitGasoline Sending Unit Gasket

HornAdapter, Oil Gauge

Pressure Hose, Oil Gauge

Electric Oil Pressure Sending UnitKnob

Push Button

Spring

Ground Wire

Horn WireStarter Cable

Battery Cable

Ground Cable

Hour Meter Ground Wire

Wiring Harness

Ignition Wire Harness, Gasoline

Ignition Wire Harness, Propane

Starter Button Switch

Ignition Key

No. Req'd.

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Outer Mast BB" LiftC)uter Mast 106" LiftOuter Mast 120" LiftOuter Mast. 130" LiftOuter Mast, 14+" L:lftInner Mast BB" LiftInner Mast 106" LiftInner Mast 120" Liftfnner Mast, 130" LiftInner Mast, 14+" LiItLift Chain. BB" Lift f 6H5 Leaf Chain. 103P

Lift Chain. 106" Lift f 6H5 Leaf Chain, 115P

Lift Chain, 120" Lift f6H5 Leaf Chain, 125P

Lift Chain. 130" Lift f 6H5 Leaf Chain 133P

Lift Chain, 141" Lift f 6H5 Leaf Chain 144PPrior to Serial No. 31001 order No. 100,585Lift Chain. f 50 Rollcr Chain (Specify Lift Height)Free Lift Chain. BB" Lift f 6H5 Leaf Chain. 161P

Free Lift Chain. 106" Lift, .f6H5 Lcaf Chain. l75PFree Lift Chain. 120" Lift. #6H5 Leaf Chain. 1B3PPrior to Serial No. 33001 Order No. 100.339Free Lift Chain. 106" Lift, #6H5 Leaf Chain, 67P

/+" Grease ZerkLift Pin Bolt/2" Lock Washer

/2"'\NasherBushing 1" ID x 1%' OD x 1/2" LongLift Sheave. Prior to Serial No. 31001 order No'

100,039 Lift SprocketFree Lift Chain SheaveT.ift PinFree Lift PinAdjustment Boit. Prior to Serial No. 31001 use No.

100.061Pin L"af Chain Connectine. Prior to Serial No. 31001 4

Use f 50 Roller Chain Connecting LinkCarriaee, Prior to Serial No. 31001 use 100,050 1

Free Lift CarriageIork 30"Fork 36"Fork 42"Quick Detachable Fork 30"

Quick Detachable Fork 36"

Quick Detachable Fork 42"Full Taper Fork 30"Full Taper Fork 36"Irrll Taper Tork 42"Quick Detachable Full Taper Fork 30"

Quick Detachable Full Taper Fork 36"

Quick Detachable Full Taoer Fork 42". Prior to SerialNo. 31001 use 100,059 (Specify Length and Style)

Fork Slide RodThrust Bearing MountThrust Bearins McGill No. CYR 1l S:ii" x |yr" Roll PinGuide Bearing McGill No. CF-2-S Prior to Serial No.

31001 Specifv McGill No. CF-1 %-S/s" Lockwasher. Prior to Serial No. 31001 use

f" Lockwasher7/B' N.F. Hex Nut. Prior to Seriai No. 31001

Use /+" N.F. Hex Nut.Hair Pin. Fork RodThrust Mount Spacer, LightThrust trIount Spacer, MediurnThrust Mount Spacer. Hcavy90' Angle Zerk, /a"-90Snap RingLift Cylindel Mount PinFree Lift Mount Pin

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Re:rr PlatformCountcrweightCounterrveight Piny's" *6" H.'I. Sockct HeadSteering CoverPrior to Scrial No. 31001 Use No. 100.119t/t,'x1'1" Roll Pin 2

Steering U-Joint, Lower 1

%" *2/"" Hex Hcad Cap Screw 3

Lock Ring, Pinion 1

Prior to Serial No. 32017 Usc No. 100,112Needle Be:rring Torrington 8-1416 2

Prior to Serial No. 32017 Use No. 100.581Bushing %" ID. x 1" O.D. x 1" LongPinion Take Up Slecve 1

Prior to Serial No. 32017 use No. i00,111Steering Gear Pinion 1

Prior to Serial No. 32017 use No. 100.110Hub Cap 1

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Prior to Serial No. 32017 use No. 100.101

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Prior to Scrial No. 32017 use No. 100.1091"-B N.C. Castellated Nut 1

Prior to Serial No. 32017 use 1" N.F. Self Lock NutPrior to Serial No. 31001 use 100,572 %" N.F.Self Lock NutSeal C,/R 275-W2-M1 2

Prior to Serial No. 32017 use 100,668 C/R225HD112Prior to Serial No. 31001 Seal is integral with BearingClamp Flange Side Spaccr 1

Prior to Serial No.32017 use No. 100,306Prior to Serial No.31001 use No. 100.106Bearins Cone Timken No. 14137A 2

Prior to Serial No. 32017 use No. 100,666Timken No. 15578Prior to Serial No. 31001 use No. 100,574ilimkcn No. LM11949LBearing Cup Tiniken No. 14274 2

Prior to Serial No. 32017 use No. 100,667Timken No. 15520Prior to Serial No. 31001 use No. 100,575Timken No. LM119105/16" x 1" Hex Head Cap Screw 4

Lock Ring 1

Prior to Serial No. 32017 use No. 100,108Rear Tire 9x5x5 tPrior to Serial No.32017 use 8/zx4x4 TireModel 15-15 Use No. 100,576 RubberModel 20-15 Use No. 100,807 PolyurethaneNeoprene Rear Tire 9 x 5 x 5

Polyurethane Rear Tire 9 x 5 x 5

Rear Wheel 5" IPrior to Serial No. 32017 use No. 100,320,4"Prior to Serial No. 31001 use No. 100,120,4"Flange Side Spacer , IPrior to Serial No.32017 use No. 100,307Prior to Serial No. 31001 use No. 100,107Rear Axle 1

Prior to Serial No. 32017iuse 1" x 7" HTNF Cap ScrewPrior to Serial No. 31001 use %" "7" HTNF Cap.Screw

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100,392

100,376

100,382

100,389

Mount Pin

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Lift Shoe, Left

Lift Shoe, Right

26

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NAtulGc)Hydrsulic Vqlve Components

Key No. Part No.

** Housings and spools cannot be ordered as separate items. All spoolsto individual housings by select hone process at factory.

* When ordering main relief valve or parts for it refer to valve housing numberwhich is located on the drive motor valve section and visible frorn the right sideof truck and behind the mounting pad of the lower boit.

1.

,J.

100,504*x101,593x*101,594**101,595

100,872

rc|,221101,151

101,596

101,522101,597

101,521

t}r,527100,901

101,525

t01,322101,526101,598101,528

101,523

101,599

101,524101,600101,005

100,717

100,348101,601

* 101,328*101,496*101,602*101,603*101,604t6101,605

*101,125e101,49+

100,75010t,329101,319101,606101,318

101,607

Description

Hydraulic Valve Assembly

Drive Motor Valve Section (Includes Spool)Lift Valve Section (Includes Spool)Tilt Valve Section (Includes Spool)Auxiliary Valve Section Double Acting

(/e" *7/2" Cap Screws Req'd.)Valve Section Seal KitCylinder Port PIug O'Ring fiBCylinder Port Plug f B

z/s" x5/2" Cap ScrewCheck PlugO-Ring ff14Check SpringCheck Poppet

Quad Ring Seal

Stop CollarCentering SpringSpool CollarSpool Assembly LockwasherSpool Assembly Screw

BonnetRonnet Screw with LockwasherBonnet DiaphramHandle Adapter LockwasherHandle AdapterBlock Vee Ring C/R 711810

Handle Bracket with Seal 100,717

Handle Bracket Screw with LockwasherMain relief Valve Assembly (Housing No. 1724)

Main relief Valve Assembly (Housing No. 3001)

O-Ring and Seal (Housing No. 1724)

O-Ring and Seal (Housing No. 3001)

O-Ring and Back-up Washer (Housing No. 1724)

O-Ring and Back-up Washer (Housing No. 3001)

Copper Gasket (Housing No. 1724)

O-Ring (Housing No. 300i)GasketTilt Relief Valve Assembly

Inner O-Ring Seal

O-RingLift Relief Valve AssemblyO-Ring

No. Req'd.

1

1

1

L'

1

2

1

1

+

J

J

J

J

6

6

J

J

J

3

.l

2

3

J

J

3

J

2

1

1

1

1

1

Ii1

1

2

3

J

1

1

are fitted

4.

5.

6.

7.

B.

9.

10.

11.

T2,

13.

t4.15.

16.

t7.18.

19.

20.

21.22.23.2+.

25.26.

27.

28.

29.

30.

31.

32.JJ.

3+.

35.

-1.sr'W

q'il

ir1iI

J

l

J

i

i -. ---*_-

WcrrrqnfyNAM Co. warrants each product of its manufacture to be free fromdefective material and workmanship if the product is operated andserviced accordinq to the manufacturer's instruction manual.

This warranty is in effect for 90 days from date of purchase or for300 operating hours as indicated on the engine hour meter, which-ever shall come first.

NAM Co. obligation under this warranty is limited to repair orreplacement of parts ONLY which have been returned to the NAMCo. factory freight prepaid, and after inspection, are deemed byNAM Co. to be defective. The warranty obligation is in no way tobe construed to include labor or other miscellanous costs or loss ordamages incurred directly or indirectly from the use of the NAMCo. products.

This u'arranty shall not apply to component parts rvhich are war-ranted separately by their respective manufacturers.

Neither shall this warralrty apply to any parts or components whichare expendable and are expected to rvear out in normal service dur--ing the course of this warranty.

This u'arranty supersedes all other lvarranties, expressed or implieci,and no person, agent or dealcr i.-s authorized to give any other lvar-ranties on behalf of the manufacturer.

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