Manual Intercambiador

Symbol Identification Chart
Refer to accompanying
Refer to Manual.
documentation.
Do not operate without all Crush Hazard – Keep Hands

guards and covers in place. Clear.
Entanglement Hazard – From

Pinch Point Hazard
chain, gear or pulley.
Crush Hazard From Falling Crush Hazard – Keep Feet

Load Clear
Eye Protection Required Safety Shoes Required
Heavy Object – Do not exceed

Slip Hazard
recommended load weight.
Protective Clothing Required Rubber Gloves Required
2
Dangers, Warnings and Cautions
! DANGER! ! CAUTION!
Only certified operators should To reduce the risk of collision,
attempt to lift/carry loads with this unit. ensure unit is positioned for
Keep area under load clear when optimal visibility.
operating unit.
Use care when transporting

Do not attempt to pull loads in load over wet floor/surface.
excess of 2,500 lbs. (1,134kg).
Back injury or muscle strain
may occur. Use care when
operating on an incline.
Eye protection, safety

shoes and protective
Do not attempt to operate this
clothing are required
equipment if you are impaired (ill,
when operating this
under the influence of medication,
equipment.
alcohol, etc.). Errors in operation can
cause hazardous and potentially
LETHAL conditions.
LBL-003
! CAUTION! ! CAUTION!
Operating temperature range for the
Do not operate without all
battery is from -20°C to +50°C. Do not
guards, covers and panels in
use outside of manufacturer's
place.
recommendations. LBL-011 LBL-018
! WARNING! ! WARNING!
Crush Hazard! Crush Hazard!
Keep hands clear. Keep feet clear.
LBL-025 LBL-015
! CAUTION! ! WARNING!
Pinch Point! Moving Parts!
Keep hands clear. Keep hands and
LBL-016 fingers clear. LBL-017
FORK HERE
LBL-049
3
This manual contains important information to help you properly operate and maintain
your “BATTERY TUGGER” for maximum performance, economy and safety.
By practicing correct operating procedures and by carrying out the recommended
preventive maintenance suggestions, you will experience long, dependable and safe
service.
TABLE OF CONTENTS
TABLE OF CONTENTS ..............................................................................................................................................4
GENERAL INFORMATION ........................................................................................................................................5
Pallet Truck Front Mounting (Figure – 1a)....................................................................................................................6
Fork Truck Front Mounting (Figure – 1b) .....................................................................................................................6
Fork Truck Side Mounting (Figure – 1c).......................................................................................................................6
Battery Tugger / Lift Truck positioning (Figure – 2) ....................................................................................................7
Operating Instructions ...................................................................................................................................................8
Extraction from the Lift Truck: .....................................................................................................................................9
Battery Tugger Assembly (Figure – A1.1) .................................................................................................................. 10
Battery Tugger Assembly with 24V VS Panel (Fig. – A1.2)....................................................................................... 11
Battery Tugger Assembly with Remote Pendant (Fig. – A1.3) ................................................................................... 12
Battery Tugger Assembly with 24V VSJ (Figure – A2) .............................................................................................. 13
Battery Tugger Assembly (Figure – A3) ..................................................................................................................... 14
Battery Tugger Assembly (Figure – A4) ..................................................................................................................... 15
Battery Tugger Assembly (Figure – B) ....................................................................................................................... 16
Battery Tugger Assembly (Figure – C) ....................................................................................................................... 17
Battery Tugger Assembly (Figure – D) ....................................................................................................................... 18
Battery Tugger 24V Standard Assembly (Figure – E1) ............................................................................................... 19
Battery Tugger 24V VS Assembly (Figure – E1.2) ..................................................................................................... 20
Battery Tugger 24V VSJ Assembly (Figure – E2) ...................................................................................................... 21
Battery Tugger Assembly (Figure – E3)...................................................................................................................... 22
Battery Tugger Assembly (Figure – E4)...................................................................................................................... 23
2 Button and 1 Switch Assembly (Figure – F1) .......................................................................................................... 24
Battery Tugger Assembly (Figure – F2) ...................................................................................................................... 25
2 Button and 1 Switch With Coiled Cord Assembly (Figure–F3) ............................................................................... 26
Potentiometer Style 24V Variable Speed Switch Assembly (Figure–F4) ................................................................... 27
Potentiometer Style 36V,38V Variable Speed Switch Assembly (Figure–F5)............................................................ 28
Safety Arm and Battery Folded Guide Assembly and Aluminium / Steel Drop In (Optional) (Figure – G) ............... 29
Safety Arm and Battery Guide Assembly and Aluminium / Steel Drop In (Optional) (Figure – G') .......................... 30
Battery Folded Guide Assembly (Optional) (Figure – G1) ......................................................................................... 31
Aluminium Drop In Assembly(Optional) (Figure – G2) ............................................................................................. 32
Steel Drop In Assembly(Optional) (Figure – G3) ....................................................................................................... 33
Battery Tugger Step Assembly(Optional) (Figure – H)............................................................................................... 34
Battery Tugger Step Assembly(Optional) (Figure – H1)............................................................................................. 35
Electrical Schematic 24V Standard(Figure – 3.1) ....................................................................................................... 36
Electrical Schematic 24 Curtis Controller VS (Figure – 3.2) ...................................................................................... 37
Electrical Schematic 24V VSJ Control (Figure –3.3) .................................................................................................. 38
Electrical Schematic 36V & 48V Standard(Figure – 3.4) ........................................................................................... 39
Electrical Schematic 36V,48V Variable Speed (Figure – 3.5) .................................................................................... 40
Electrical Schematic 80V DC (Figure –3.6) ................................................................................................................ 41
Battery Tugger Quick Clamp (Figure – 4)................................................................................................................... 42
Battery Tugger Quick Clamp (Optional) (Figure – 4.1) .............................................................................................. 43
Electromagnet Maintenance (Figure – 5) .................................................................................................................... 44
Drive Mechanism Maintenance (Figure – 6) ............................................................................................................... 45
Slider Strip Maintenance (Figure – 7) ......................................................................................................................... 46
Fork Truck Safety Chain (Figure – 8) ......................................................................................................................... 47
Torque Tamer Adjustment ........................................................................................................................................... 48
Torque Tamer Installation Instructions (Figure – 9).................................................................................................... 49
STATEMENT OF WARRANTY ............................................................................................................................... 51
HOW TO PLACE AN ORDER FOR PARTS ............................................................................................................ 52
4
GENERAL INFORMATION
Congratulations on purchasing a new “ BATTERY TUGGER”. With the proper care and
regular maintenance you will receive years of trouble free service.
If you require technical support or other repair services, or if you are ordering
replacement parts, please provide us the following information.
Model: H-BTE-30-24-FM-CL-VSJ
Serial No.: CMC0001
Power Source: 24V 50A
Note:
If your Tugger is equipped with an emergency stop button and it is
activated, you must wait 20 seconds before pulling the button back up
(This is required for the controller to re-boot itself)
5
Pallet Truck Front Mounting (Figure – 1a)
Fork Truck Front Mounting (Figure – 1b)
Fork Truck Side Mounting (Figure – 1c)
6
Battery Tugger / Lift Truck positioning (Figure – 2)
Example Showing Extraction Using Pallet Truck
7
Operating Instructions
Battery Tugger
Description:
The Battery Tugger is a non-propelled, electrically powered battery changer that is
designed for medium volume applications and all sizes of batteries, such as those found
in reach trucks, pallet trucks and 3 & 4 wheel counter-balance trucks.
Before operating the “ BATTERY TUGGER” it must be mounted onto a mobile lift truck
or pallet truck as shown in figure #1a, b or c. It is important that the operator thoroughly
review and understand the proper Safety Procedures and Instructions as outlined in this
Owner’s Manual and the Owner’s Manual for the mobile truck. It is also important that
the “ BATTERY TUGGER” be secured to the mobile lifting truck, either bolted
permanently or chained. Fastening is recommended however fastening can be quick
release to allow the host truck to be used in regular operations.
All operators must be trained or certified (if required) in the use of the “BATTERY
TUGGER”.
Safety shoes, safety glasses and protective clothing are mandatory in Battery
Rooms. Be sure to wear them at all times. Rubber gloves, rubber aprons and
full face shields are required when washing and servicing forklift batteries.
Always use caution and common sense.
Preparation:
1. Park the lift truck in a perpendicular position adjacent to the “ BATTERY TUGGER”
(figure #2, page #5).
2. Prepare the lift truck for battery removal as follows:
 Lower the forks until they sit flat on the floor.

 Engage the parking brake.
 Remove any protective covers.
 Unplug the battery and position the connector plug
And cable so as to prevent snagging or pinching during
the battery removal process.
 Remove the battery retaining gate.
8
Extraction from the Lift Truck:
1. Position the Battery Tugger in front of the battery compartment and lower the unit so
the front rollers are approximately ½” below the bottom of the battery to be removed.
2. Power the magnet out until it contacts the battery to be removed. Then turn on the
magnet toggle switch. Power the magnet back to pull the battery out, until it is just
over the large black entry rollers on the Battery Tugger.
3. Raise the Battery Tugger using the forklift controls until the rollers support the weight
of the battery, and continue to pull the battery all the way into the Battery Tugger.
4. Drive the forklift to an appropriate empty roller stand.
5. Raise or lower the Battery Tugger to the roller stand height, then power the magnet
to push the battery out onto the roller stand.
Insertion into the Lift Truck:
1. Raise the Battery Tugger using the mobile lifting truck controls to the roller stand
level and retrieve the charged battery.
2. Position the Battery Tugger in front of the lift truck battery compartment , and then
raise or lower the battery to be just slightly above (approx. ½”) the level of the lift
truck’s roller or slider bed.
3. Power the magnet and battery as far as it will go into the lift truck. If using a powered
pallet truck, make sure the pallet jack handle is in the vertical position, i.e. brakes
are on.
Conclusion:
1. Drive the “BATTERY TUGGER” away from the lift truck and park it in a safe
location.
2. Check the discharged battery, connect the cables and turn on the charger.
3. Prepare the lift truck for operation as follows:
 Install the battery retaining gate
 Plug in the battery
 Install the protective covers
 Check the battery indicator gauge
9
Battery Tugger Assembly (Figure – A1.1)
PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
10 1 BT-570 OPERATOR CTRL BRACKET
34 1 BT-E-839-1 24V DC ELECTRICAL PANEL
## FIG.-X 1 35 1 CBS-3926 2 BUTTON & 1 SWITCH ASSEMBLY
36 2 CBS-3935 HEX BOLT
37 2 CBS-1455 FINISHED HEX NUTS
38 2 CBS-1462 FLAT WASHERS
# 44 1 BT-E-XX-015 COVER
FIG.-B
# 45 1 BT-XX-BRC BLACK RUBBER
48 5 CBS-3727 HEX HEAD CAP SCREW
49 5 CBS-3728 HEX FLANGE NUT
56 2 CBS-2418 BOLT HEX HEAD
FIG.-C 58 2 CBS-2415 BOLT HEX HEAD
62 4 CBS-3732 CROSS RECC. PAN HEAD MACH SCREW
63 4 CBS-3733 HEX NUT
EMERMENCY DISCONNECT SWITCH
64 1 CBS-3117 (OPTIONAL)
FIG.-D
# NOTE:
XX - 24 FOR WIDTH 24" TUGGER
30 FOR WIDTH 30" TUGGER
## NOTE:
X - A1.1 FOR TUGGER WITH 24V DC STANDARD
64
58
44
48
49
FIGURE A1 ASSEMBLY
45
34
FIG.-F1
35
62 40
63 FIG.-E1
10
37
56
38
57 36
REV DATE REVISON BY
UPDATE: Sep. 25, 2012 1 Feb 3,2012 Replace CBS-3765 BY CBS-3926 MW
10
Battery Tugger Assembly with 24V VS Panel (Fig. – A1.2)
PARTS LIST
34 1 BT-E-839-4 24V DC CURTIC CONTROLLER PANEL
## FIG.-X 35 1 BT-837-4 VARIABLE SPEED SWITCH (KNOB)
FIG.-B
FIG.-D
# NOTE:
## NOTE:
X - A1.2 FOR TUGGER WITH 24V DC CURTIS
CONTROLLER VARIABLE SPEED
ELECTRICAL PANEL
64
58
44
48
49
FIGURE A1.2 ASSEMBLY

45
35
34
FIG.-F4
62
FIG.-E1.2
63
10 40
37
56 38
57 36
UPDATE: Jan.28, 2013 REV DATE REVISON BY
11
Battery Tugger Assembly with Remote Pendant (Fig. – A1.3)
PARTS LIST
## FIG.-X 1 35 1 CBS-3926 2 BUTTON & 1 SWITCH ASSEMBLY
FIG.-B
56 1 CBS-2147 EYE BOLT
FIG.-D
# NOTE:
## NOTE:
X - A1.3 FOR TUGGER WITH 24V DC STANDARD
WITH REMOTE PENDANT BUTTON
64
58
44
48
49
FIGURE A1 ASSEMBLY
45
34
56 57
FIG.-F3
40
35 FIG.-E1
62
10
63
37
38
36
REV DATE REVISON BY
UPDATE: Oct.22, 2012 1 Feb 3,2012 Replace CBS-3765 BY CBS-3926 MW
12
Battery Tugger Assembly with 24V VSJ (Figure – A2)
PARTS LIST
# NOTE: 10 1 BT-629 OPERATOR CTRL BRACKET
XX - 24 FOR WIDTH 24" TUGGER 34 1 BT-E-839-1 24V ELECTRICAL PANEL
30 FOR WIDTH 30" TUGGER 1 35 1 FIG.-F2 JOYSTICK CONTROL ENCLOSURE
## FIG.-X 36 2 CBS-3935 HEX BOLT
40 1 BT-E-840 24V VARIABLE SPEED JOYSTICK
ELECTRICAL PANEL
FIG.-B 48 5 CBS-3727 HEX HEAD CAP SCREW
FIG.-C
62 2 CBS-3948 ROUND HEAD MACHINE SCREW
63 2 CBS-3949 FLAT WASHER
CBS-3117 EMERMENCY DISCONNECT SWITCH
64 1 (OPTIONAL)
FIG.-D
## NOTE:
X - A2 FOR TUGGER WITH 24V DC CURTIS JOYSTICK
VARIABLE SPEED ELECTRICAL PANEL
FIGURE A2 ASSEMBLY
64 58
44
48
49
45
34
62
63
FIG.-F2
35
FIG.-E2
10 40
37
56 REV DATE REVISON BY
38
1 Nov.13,2012 Replace BT-835 With Fig.-F2 MW
57 36 Title: BTE-Curtis Controller VSJ Assembly Fig-A2
Drawn By: M.W. Date: Feb 20,2013
13
Battery Tugger Assembly (Figure – A3)
14
Battery Tugger Assembly (Figure – A4)
34 1 BT-E-839-1 24V ELECTRICAL PANEL
1 35 1 CBS-3926 2 BUTTON & 1 SWITCH ASSEMBLY
## FIG.-X 36 2 CBS-3935 HEX BOLT
40 1 FIGURE E4 ELECTRICAL TUGGER 80V DC PANEL
FIG.-B
56 1 CBS-2147 EYE BOLT
FIG.-C 62 4 CBS-3732 CROSS RECC. PAN HEAD MACH SCREW
64 1 CBS-3117 EMERMENCY DISCONNECT SWITCH
(OPTIONAL)
# NOTE:
FIG.-D XX - 24 FOR WIDTH 24" TUGGER
## NOTE:
X - A4 FOR TUGGER WITH 80 VDC ELECTRICAL PANEL
64
58
44
48
49
FIGURE A4 ASSEMBLY
45
34
56 57
FIG.-F3 40
35
62
FIG.-E4
10
63
37
38
36
REV DATE REVISON BY
DATE: Sep.23,2012 1 Feb 3,2012 Replace CBS-3765 BY CBS-3926 MW
15
Battery Tugger Assembly (Figure – B)
# NOTE: # 7 1 BT-E-XX-011 Bridge Drive Shaft
XX - 24 FOR WIDTH 24" TUGGER 8 1 CBS-127 Bearing
30 FOR WIDTH 30" TUGGER 9 2 CBS-1324 Bearing *
## FIG.-X 36 FOR WIDTH 36" TUGGER 13 3 CBS-364 Sprocket *
42 FOR WIDTH 42" TUGGER 15 1 CBS-3748 Motor
48 FOR WIDTH 48" TUGGER 1 21 1 CBS-3943 Torque Tamer *
30 4 CBS-2474 Hex Bolt
32 6 CBS-3722 Large Hex Flange Nut
33 1 CBS-3705 Reducer
FIG.-B 47 1 CBS-360-28.5 Chain *
48 1 CBS-362 Link *
55 4 CBS-3782 Hex Head Bolt
56 4 CBS-1142 Lock Washer
57 8 CBS-1143 Flat Washer
FIG.-C
58 4 CBS-1570 Hex Nut
59 2 CBS-278 Single Split Collar
2 60 2 BBH-510 Spacer Ø1-1/2XØ1.0X1/4
3 61 2 CBS-109 Double Split Lock Collar
FIG.-D 62 1 Keystock 1/4X2-1/4 *
63 1 Keystock 1/4X1-1/4 *
5 64 1 CBS-4214 Socket Head Screw
4 66 1 BT-857 Motor Output Shaft Bushing
* : RECOMMENDED SPARE PARTS
## NOTE:
X - A1 FOR TUGGER WITH 24V DC ELECTRICAL PANEL
A2 FOR TUGGER WITH 24V VARIABLE SPEED
JOYSTICK ELECTRICAL PANEL
A3 FOR TUGGER WITH 36V/48V/VARIABLE SPEED
FIGURE B ASSEMBLY POTENT 10 METER ELECTRICAL PANEL
A4 FOR TUGGER WITH 80VDC ELECTRICAL PANEL
15
33
58 57 56 55
63
21
66
31
65
62 7
64
47 32
48 8
32
30
61
13
5 Sep 30,2013 Replace CBS-3954 with CBS-4214 MW
13 4 Aug 29,2012 Replace CBS-3853 with BT-857 MW
60 3 Mar 5,2012 Add Item 61 MW
9 2 Mar 5,2012 Add Item 60 MW
59 1 Feb 23,2012 Replace CBS-3169 with CBS-3943 MW
REV DATE REVISON BY
16
Battery Tugger Assembly (Figure – C)
PARTS LIST
# 16 1 BT-XX-102-W TUGGER BRIDGE WELDMENT
17 1 BT-522-A MAGNET PIN WELDMENT
18 2 CBS-1330 PIN
19 1 BT-522-B PIN WELDMENT
20 1 CBS-2005 ZERK AXLE
22 1 CBS-1252 SPRING *
## FIG.-X MAG-001-24 MAGNET (8 POLES,24V)
23 1
MAG-001-90 MAGNET (8 POLES,90V) For 80V
MAG-003-24 MAGNET (10 POLES,24V)
24 1 CBS-1312 SET SCREW
25 5 CBS-3721 HEX CAP SCREW
MAG-505 ELEC. BACK PLATE COVER 8 POLE
26 1
FIG.-B
MAG-120 ELEC. BACK PLATE COVER 10 POLE
FIG.-C
50 1 CBS-511 MAGNET CURLY CORD *
BT-101-6-5.75-W MAGNET ARM 6" LONG (for DIS-48-2)
MAGNET ARM 6" LONG
BT-101-6-6.75-W
(for DIS-48-3 & DIA-48-3.5)
BT-101-6-W MAGNET ARM 6" LONG
FIG.-D 54 1
55 1 CBS-3907 NYLOCK HEX NUT
56 1 CBS-2004 WHEEL *
57 1 CBS-2006 SPANNER DRILLED
58 2 BT-518 SLIDE PAD *
60 2 CBS-3734 LOCK WASHER
62 2 CBS-1334 DOUBLE TUBE WIRE CLAMP

# NOTE:
FIGURE-C ASSEMBLY XX - 24 FOR WIDTH 24" TUGGER
53 42 FOR WIDTH 42" TUGGER
50 58
59
53
60
61
62 17
16
54
55
26
24
18
19
23
57 20 56 22 25
18
DRAWN BY: M.W. DATE: Aug.13,2013
17
Battery Tugger Assembly (Figure – D)
# 1 1 BT-E-XX TUGGER WELDMENT
3 2 BT-810 TUGGER BUMPER *
4 1 BT-825 TUGGER BUMPER LOWER FRONT
##FIG.-X 5 2 BT-597 ROLLER SHAFT *
6 2 BT-596 ROLLER *
11 2 BT-574 CHAIN GUARD
12 1 BT-805-X(R) BEARING GUARD PLATE RIGHT
14 3 BT-608 SLIDER TRIP 48" LG *
(QTY 5 FOR 36/42/48 MODELS)
19 2 CBS-3908 HEX JAM NUT
FIG.-B 23 2 BT-103 SPROCKET YOKE
24 2 BT-105 PIN *
25 4 CBS-258 RETAINING RING *
26 2 CBS-363 SPROCKET *
27 6 CBS-1498 FLAT SOCKET CAP SCREW
FIG.-C
28 3 CBS-3718 HEX SOCK FLAT CNT. HEAD SCREW
29 2 CBS-3172 FLAT SOCKET CAP SCREW
30 12 CBS-2474 BOLT HEX
31 1 BT-848 BOLT ON SLIDER STOP
FIG.-D 32 8 CBS-3722 LARGE HEX FLANGE NUT
46 2 CBS-360-112 CHAIN *
47 2 CBS-362 LINK *
51 2 BT-506 EXTERIOR COVER PLATE
52 2 CBS-3729 HEX SOCK BUTTON HEAD CAP SCREW
54 1 BT-805-X(L) BEARING GUARD PLATE LEFT
64 2 BT-833 MICRO SWITCH MTG. PLATE
65 2 CBS-3615 FLEXIBLE ROD MICRO SWITCH *
66 8 CBS-3740 HEX NUT NYLOCK
67 4 CBS-3741 SOCKET HEAD SCREW
68 4 CBS-3742 SOCKET HEAD SCREW
FIGURE D ASSEMBLY * : RECOMMENDED SPARE PARTS
# NOTE:
67 68 41 42 43 1 11 42 FOR WIDTH 42" TUGGER
64
12
65
68
64
66 65
51
66 52
32 67
25
30 24
26
23
54 27
5
46 47
6
19 29 28 31 4 27 14
DRAWN BY: M.W. DATE: Sep.28,2012
18
Battery Tugger 24V Standard Assembly (Figure – E1)
PART LIST
MOTOR CONTACTOR ASSEMBLY 100 1 BT-E-24-018 CONTACTOR BRACKET
BT-854 101 1 CBS-3759 50A FUSE *
102 1 CBS-3736 MOTOR CONTACTOR
103 4 CBS-3983 WASHER
104 6 CBS-3982 MACHINE SCREW
105 2 CBS-2102 STAND OFF RED
101 105 100 106 4 CBS-1494 LOCK WASHER
109 1 BT-E-24-016 MOUNTING PLATE
110 1 CBS-291 CONTACTOR 24VDC *
107 111 1 CBS-1216 TIMER RELAY
112 1 CBS-2100 TERMINAL STRIP
106 113 2 CBS-1840 FUSE HOLDER
114 1 CBS-1164 DIN RAIL
115 2 CBS-411 TERMINAL BLOCK
108 116 1 CBS-1413 TERMINAL END BLOCK
118 1 CBS-1842 15A FUSE *
119 1 CBS-2103 6A FUSE *
104 103 102
24 V STANDARD ELECTRICAL PANEL ASSEMBLY
112 109
117
114
110
103
104
118
113
119 104 111 115 116
DRAWN BY: M.W. DATE: Apr 19,2012
19
Battery Tugger 24V VS Assembly (Figure – E1.2)
PART LIST
24V CURTIS CONTROLLER VARIABLE SPEED ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION
6 BTE-854-4-VS 1 1 CBS-4106-VS Motor Controller
2 1 BT-E-24-035 Contactor Bracket
7 14 10 3 1 CBS-3736 Motor Contactor
4 3 CBS-2102 Stand Off
8 )
(- 5 1 CBS-3759 50A Fuse *
9
) 6 6 CBS-2436 Hex Bolt
4 (+
6 3 8 3 CBS-3894 Flat Washer
7
10 2 CBS-3982 Machine Screw
2
1 12 2 CBS-3887 Lock Nut
13 1 BTE-VS-C-1
14 2 CBS-719 Diode
13 15 1 BT-E-24-016 Mounting Plate
16 1 CBS-291 Contactor 24VDC *
12
17 1 CBS-1216 Timer Relay
11 18 1 CBS-2100 Terminal Strip
19 2 CBS-1840 Fuse Holder
20 1 CBS-1164 DIN Rail
21 2 CBS-411 Terminal Block
22 2 CBS-1413 Terminal End Block
4 24 1 CBS-1842 15A Fuse *
5 25 1 CBS-2103 6A Fuse *
26 1 CBS-469 Terminal Block End Cap
8
7 * : RECOMMENDED SPARE PARTS
6
24 V VARIABLE SPEED ELECTRICAL PANEL ASSEMBLY
14
18
(-) 15
23
(+ 20
)
16
10
24
19
25 10 22 17 21 26 22
UPDATE BY: M.W. DATE: Aug.16,2013
20
Battery Tugger 24V VSJ Assembly (Figure – E2)
PART LIST
24V CURTIS CONTROLLER JOYSTICK VARIABLE SPEED ASSEMBLY
BTE-854-4-VSJ
6 1 1 CBS-4106-VSJ Motor Controller
2 1 BT-E-24-035 Contactor Bracket
7 14 10 3 1 CBS-3736 Motor Contactor
4 3 CBS-2102 Stand Off
8 )
(- 5 1 CBS-3759 50A Fuse *
9
4 (+
)
6 3 8 3 CBS-3894 Flat Washer
7
2
1 12 2 CBS-3887 Lock Nut
13 1 BTE-VSJ-C-2
14 4 CBS-719 Diode
16 1 CBS-291 CONTACTOR 24VDC *
12 17 1 CBS-1216 TIMER RELAY
11 18 1 CBS-2100 TERMINAL STRIP
19 2 CBS-1840 FUSE HOLDER
20 1 CBS-1164 DIN RAIL
21 2 CBS-411 TERMINAL BLOCK
22 1 CBS-1413 TERMINAL END BLOCK
4 24 1 CBS-1842 15A FUSE *
5 25 1 CBS-2103 6A FUSE *
26 1 CBS-469 Terminal Block End Cap
8 13
7 * : RECOMMENDED SPARE PARTS
6
24 V JOYSTICK VARIABLE SPEED ELECTRICAL PANEL ASSEMBLY

14
18
15
23
20
16
10
14
24
19
25 10 17 21 26 22
DRAWN BY: M.W. DATE: Aug.16,2013
21
Battery Tugger Assembly (Figure – E3)
PARTS LIST
MOTOR CONTACTOR ASSEMBLY 100 1 BT-E-24-018 CONTACTOR BRACKET
BT-854
101 1 CBS-3759 50A FUSE *
101 105 100 104 2 CBS-3982 MACHINE SCREW
107 107 4 CBS-3984 WASHER
106
110 1 CBS-2012 MOTOR CONTROLLER
111 1 CBS-2091 RESISTOR
108
112 1 CBS-789 TIMER RELAY
113 1 CBS-1164 DIM RAIL
114 1 CBS-291 SOLENOID *
116 2 CBS-1840 FUSE HOLDER IN-LINE
117 1 CBS-1413 TERMINAL END BLOCK
104 103 102 119 1 CBS-2103 6A FUSE *
121 1 CBS-1842 15A FUSE *
122 1 CBS-2109 16 PIN PLUG
36V/48V DC STANDARD and 36V/48V DC VARIABLE SPEED
123 1 CBS-793 SOCKET
POTENTIOMETER ELECTRICAL PANEL ASSEMBLY
110
111
121 103
118
114
122
103 119
109
104
116
117
123
115 120 113 103 104 112
UPDATE 27 FEB 2013 DRAWN BY: M.W. DATE: Nov.8,2012
22
Battery Tugger Assembly (Figure – E4)
PARTS LIST
MOTOR CONTACTOR ASSEMBLY ITEM QTY PART NUMBER DESCRIPTION
100 1 BT-E-24-018 CONTACTOR BRACKET
101 105 100 101 1 CBS-3759 50A FUSE *
103 10 CBS-3983 PLAIN WASHER
107
106 106 4 CBS-1494 LOCK WASHER
108 108 4 CBS-2436 HEX BOLT
110 1 CBS-3023 SEVCON POWERPAK CONTROLLER
111 1 CBS-3137 DC CONVERTER
112 1 CBS-1216 TIMER RELAY
113 1 CBS-1164 DIM RAIL
114 1 CBS-291 CONTACTOR *
104 103 102 115 1 CBS-3138 DC CONVERTER PLUG
116 1 CBS-3025 12 PIN MOLEX PLUG
80 VDC ELECTRICAL PANEL ASSEMBLY 119 3 CBS-1840 FUSE HOLDER IN-LINE
120 3 CBS-2103 6A FUSE *
108 121 2 CBS-411 TERMINAL BLOCK
106 122 1 CBS-1413 TERMINAL END BLOCK
107 123 1 CBS-469 TERMINAL BLOCK COVER
105 124 4 CBS-3985 MACHINE SCREW
111 LOCKNUT
110 129 4 CBS-2399
116
129
107
128 103
115
124
114
120
119
104
109 122
121
123
127 117 113 103 104 112 FILE NAME: BT-24-60-E4(80VDC).dwg

DRAWN BY: M.W. DATE: Apr 19,2012
23
2 Button and 1 Switch Assembly (Figure – F1)
24
Battery Tugger Assembly (Figure – F2)
PARTS LIST
1 1 CBS-4095 CONTROL PANEL ENCLOSURE
2 1 CBS-489 * TOGLE SWITCH
3 1 CBS-2696 * JOY STICK
4 1 BTE-VSJ-C-1 18-10C SOOW CABLE CABTIRE 4FT
5 1 CBS-2086 * IN LINE CONNECT 5 PIN
6 1 CBS-2113 STR. CONECTOR 2 SCREW
7 1 CBS-1823 LOCK NUT
8 1 LBL-177 LABEL
1
CUSTOMER ORDER PARTS:
CAN REFERENCE BTE-835
5
TITLE: JOYSTICK CONTROL ENCLOSURE WITH SOOW CABLE 18-10C

DRAWN BY: M.W. DATE: Sep.11,2013 DWG NO. BTE-835
25
2 Button and 1 Switch With Coiled Cord Assembly (Figure–F3)
26
Potentiometer Style 24V Variable Speed Switch Assembly (Figure–F4)
27
Potentiometer Style 36V,38V Variable Speed Switch Assembly (Figure–F5)
28
Safety Arm and Battery Folded Guide Assembly and Aluminium / Steel Drop In (Optional) (Figure – G)
PART LIST
7 ## 1 1 JOB# XXXXX BATTERY GUIDE ASSEMBLY (LEFT)
## 2 1 JOB# XXXXX BATTERY GUIDE ASSEMBLY (RIGHT)
11 3 2 20477-BG-07 JOINT SHAFT
15 4 2 CBS-3977 HEX HEAD MACHINE SCREW
12 5 2 CBS-4023 FLAT WASHER
6 2 CBS-3870 HEX MACHINE SCREW NUT
13
7 1 BT-831 TUGGER SAFETY GATE ARM
14 8 1 BT-844 TUGGER SAFETY GATE BRACKET (L)
9
9 1 BT-845 TUGGER SAFETY GATE BRACKET (R)
13 10 10 1 HEX SOCKET FLAT HEAD SCREW
CBS-4019
8 12 6 CBS-3714 LOCK WASHER
14 1 CBS-1544 HEX LOCK NUT
5 ALDPIN-48-Y ALUMINIUM DROP IN ASSEMBLY Y" HIGH DROP IN
# 15 2
4 DIS-48-Y STEEL DROP IN ASSEMBLY Y" HIGH DROP IN
6
NOTE: ##: XXXXXX STANDS FOR JOB NUMBER
3 # : Y STANDS FOR HEIGHT OF ALUMINIUM DROP IN
OR STEEL DROP IN
DRAWN BY: MW DATE: Oct.19,2012

29
H-BTE Manual Hawker Rev15/03/2012
Safety Arm and Battery Guide Assembly and Aluminium / Steel Drop In (Optional) (Figure – G')
PARTS LIST
2 16 2 8 CBS-1455 HEX NUT
18 6
3 1 BT-844 TUGGER SAFETY GATE BRACKET (L)
8 14 4 1 BT-845 TUGGER SAFETY GATE BRACKET (R)
12 5 1 BT-831 TUGGER SAFETY GATE ARM
## 6 1 JOB# XXXXX BATTERY GUIDE (R)
## 7 1 JOB# XXXXX BATTERY GUIDE (L)
8 2 BT-610-23.813 SLIDER TRIP 23.813" LONG *
17
9 2 CBS-3729 HEX SOCKET FLAT HEAD SCREW
10 1 CBS-4019 HEX SOCKET FLAT HEAD SCREW
11 1 CBS-1544 HEX LOCK NUT
8 9 12 6 CBS-3714 LOCK WASHER
7 13 4 CBS-3857 HEX CAP SCREW
5 17 2 BT-E-24-034 STOP BLOCK
ALDPIN-48-Y ALUMINIUM DROP IN ASSEMBLY Y" HIGH
# 18 2
DIS-48-Y STEEL DROP IN ASSEMBLY Y" HIGH
13
12
NOTE: ##: XXXXXX STANDS FOR JOB NUMBER
# : Y STANDS FOR HEIGHT OF ALUMINIUM DROP IN
1
OR STEEL DROP IN
15 4
11
1 For this Tugger Job#
10
3
30
Battery Folded Guide Assembly (Optional) (Figure – G1)
ITEM QTY PART NUMBER DESCRIPTION ITEM QTY PART NUMBER DESCRIPTION
1 2 BT-E-24-034 STRIP STOP BLOCK 8 2 CBS-3984 FLAT WASHER
2 2 CBS-1571 HEX SOCKET FLAT COUNTERSUNK HEAD SCREW 9 2 CBS-3734 LOCK WASHER
3 2 20477-BG-05 SPACER BLOCK 10 2 CBS-1459 HEX CAP SCREW
4 2 CBS-4026 BRIDGE GUARD SPACER 11 4 CBS-1143 FLAT WASHER
5 2 20477-BG-04 LOCK HANDLE 12 2 CBS-1142 LOCK WASHER
6 2 CBS-3902 HEX BOLT 13 2 CBS-1570 HEX NUT
7 2 BT-610-29 SLIDER STRIP 29" LONG * 14 1 JOB#XXXXX BATTERY GUIDE BODY WELDMENT (RIGHT)
15 1 JOB#XXXXX BATTERY GUIDE BODY WELDMENT (LEFT)
NOTE: * : RECOMMENDED SPARE PART 6 10 3

##: XXXXXX STAND FOR JOB NUMBER 11
For this Tugger Job# " 8
5
9
11
12
13
15
14
7
1
2
DRAWN BY: MW DATE: SEP.27,2012
31
Aluminium Drop In Assembly(Optional) (Figure – G2)
PART LIST
1 1 ALDPIN-48-Y-01 ## PLATE 48X11-11/32X3/16
2 2 BT-DPIN48-SS SLIDER STRIP 1-1/2X1/2, 48 LG *
4 14 CBS-1447 HEX SOCKET FLAT COUNTERSUNK CAP SCREW
CBS-4083 for Y=1"
CBS-4006 for Y=2"
5 1 CBS-4037 for Y=2.5" HEX BOLT
CBS-4024 for Y=3"
CBS-4060 for Y=4"
6 1 ALDPIN-48-3-03 FB 3X1/4,7-3/4 LG
* : RECOMMENDED SPARE PART

##: Y STANDS FOR HEIGHT OF ALUMINIUM DROP IN
2 For this Tugger Job#xxxxxx, Y=xx"

4
9
5
1
3
DWG TITLE: ALUMINIUM DROP IN ASSEMBLY Y" HIGH

DRAWN BY: MW DATE: Oct.30,2012 DWG NO. ALDPIN-48-Y
32
Steel Drop In Assembly(Optional) (Figure – G3)
PART LIST
1 1 DIS-48-Y ## STEEL DROP IN WELDMENT
2 2 BT-DPIN48-SS SLIDER STRIP 1-1/2X1/2, 48 LG *
4 14 CBS-1447 HEX SOCKET FLAT COUNTERSUNK CAP SCREW
CBS-4083 for Y=1"
CBS-4006 for Y=2"
5 1 CBS-4037 for Y=2.5" HEX BOLT
CBS-4024 for Y=3"
CBS-4060 for Y=4"
* : RECOMMENDED SPARE PART

##: Y STANDS FOR HEIGHT OF STEEL DROP IN
2 4
For this Tugger Job#xxxxxx, Y=xx"
DWG TITLE: STEEL DROP IN ASSEMBLY Y" HIGH DROP IN

DRAWN BY: MW DATE: Oct. 30,2012 DWG NO. DIS-48-Y
33
Battery Tugger Step Assembly(Optional) (Figure – H)
PART LIST
1 1 BT-STEP-XXXXXX-L BATTERY TUGGER STEP ASSEMBLY (LEFT)
2 1 BT-STEP-XXXXXX-R BATTERY TUGGER STEP ASSEMBLY (RIGHT)
XXXXXX STANDS FOR JOB NUMBER

For this Tugger Job#
1
2
2
34
Battery Tugger Step Assembly(Optional) (Figure – H1)
1 1 BT-STEP-XXXXXX-L BATTERY TUGGER STEP WELDMENT (LEFT) ##
2 1 BT-STEP-XXXXXX-R BATTERY TUGGER STEP WELDMENT (RIGHT) ##
3 2 BT-610-46.75 SLIDER STRIP 46.75" LONG *
4 2 CBS-1571 HEX SOCKET FLAT COUNTERSUNK HEAD SCREW
5 2 BT-830 STEP SLIDER STOP FRONT
NOTE: * : RECOMMENDED SPARE PART

##: XXXXXX STAND FOR JOB NUMBER
For this Tugger Job#
NO.: REVISION DATE:

TITLE: BUTTERY TUGGER STEP ASSEMBLY
DRAWN BY: MW DATE: Oct.23,2012
35
Electrical Schematic 24V Standard(Figure – 3.1)
ELECTRICAL TUGGER 24 V DC STANDARD
24 V BATTERY
50 A
FUSE
BATTERY BATTERY
CONNECTORS CONNECTORS
MOTOR
15 A 6A CONTACTORS
FUSE FUSE
DC
MOTOR MOTOR 24 V DC
EXTENDED
FORWARD LIMIT SWITCH
FORWARD
PUSH BUTTON CONTACTOR
RETRACTED
REVERSE LIMIT SWITCH REVERSE
TIMER CONTACT
MAGNET MAGNET
TOGGLE SWITCH CONTACTOR
TIMER
MAGNET
NOTE:
WIRES ON UNIT IDENTIFIED BY NUMBERS SHOWN
TITLE:
ELECTRICAL TUGGER 24V DC
DESIGNED: D.S 04/10/2011 CAD File:
36
Electrical Schematic 24 Curtis Controller VS (Figure – 3.2)
REVISION HISTORY
REV DESCRIPTION DATE APPROVED
1 REVERSE BLOCKING DIODE REMOVED 20/12/2012 J.B
ELECTRICAL SCHEMATIC 24V CURTIS CONTROLLER VARIABLE SPEED
BATTERY
+ -
BATTERY
CONNECTORS B+ B- BATTERY
CONNECTORS
(+) (-)
CONTROLLER
MOTOR
EMERGENCY CONTACTOR
DISCONNECT SWITCH
(optional)
M2 M1
FUSE 50A
FUSE 15A
DC
MOTOR
MOTOR 24 V DC
FUSE 6A
ORANGE/BLACK
WHITE/BLACK
PHO
WI
SP
PLI
PHO
PLI
SP
WI
BLUE
5K 5
GREEN/BLACK SPEED POT
RED
B- (0)
FORWARD EXTENDED
PUSH BUTTON 1 WHITE LIMIT SWITCH
2 3
REVERSE RETRACTED
PUSH BUTTON 1 5 6 BLACK LIMIT SWITCH 4 0 MOTOR
CONTACTOR
RED/BLACK MAGNET ON
0 LED LIGHT
MAGNET
TOGGLE SWITCH TIMER CONTACT (optional)
1 ORANGE 8 0 MAGNET
9
CONTACTOR
0 MAGNET
TIMER
10 0
MAG MAGNET
NOTE:
TITLE:
BTE 24V CURTIS CONTROLLER VARIABLE SPEED
DESIGNED: M.W. 04/06/2013 CAD File:
37
Electrical Schematic 24V VSJ Control (Figure –3.3)
ELECTRICAL SCHEMATIC 24V CURTIS CONTROLLER

JOYSTICK VARIABLE SPEED
BATTERY
+ -
BATTERY B+ B- BATTERY
CONNECTORS (+) (-) CONNECTORS
CONTROLLER
MOTOR
EMERGENCY CONTACTOR
DISCONNECT SWITCH
(optional)
M2 M1
FUSE 50A
FUSE 15A
DC
MOTOR
MOTOR 24 V DC
FUSE 6A
B- (0)
B- (NEG)
BLACK
AUX. B
WHITE
B- (NEG)
FORWARD EXTENDED
WHITE / BLACK TRACE
PUSH BUTTON JOYSTICK LIMIT SWITCH
AUX. A A 2
RED / BLACK TRACE
REVERSE SIGNAL
RETRACTED
PUSH BUTTON BLUE
LIMIT SWITCH MOTOR
B 3 4
GROUND C2 CONTACTOR
VS
RED
1
BLACK GREEN / BLACK TRACE 0
MAGNET ON
LED LIGHT
RED ORANGE / BLACK TRACE (optional)
MAGNET TIMER CONTACT

TOGGLE SWITCH 1 6 5 0 MAGNET
C1
CONTACTOR
0 MAGNET
TR
TIMER
C1 7 0
MAG MAGNET
NOTE:
TITLE:
BTE 24V CURTIS CONTROLLER JOYSTICK VARIABLE SPEED
DESIGNED: M.W. 28/06/2013 CAD File:
38
Electrical Schematic 36V & 48V Standard(Figure – 3.4)
ELECTRICAL TUGGER 36 OR 48V DC STANDARD
MOTOR
CONTACTOR
DC
MOTOR MOTOR 24 V DC
EXTENDED
FORWARD
RETRACTED
TIMER CONTACT
MAGNET MAGNET
MAGNET
TIMER
UNIVERSAL 24-240 V
MAGNET
NOTE:
TITLE:
ELECTRICAL TUGGER 36 OR 48V DC
39
Electrical Schematic 36V,48V Variable Speed (Figure – 3.5)
ELECTRICAL SCHEMATIC 36V, 48V

POTENTIOMETER STYLE VARIABLE SPEED
MOTOR
CONTACTOR
DC
MOTOR MOTOR 24 V DC
EXTENDED
FORWARD
RESISTOR (R2 & R3)
5 OHM 50W
(0) - 24VDC
RETRACTED (1) - 36VDC
LIMIT SWITCH (2) - 48VDC
REVERSE REVERSE
RESISTOR
TIMER CONTACT
MAGNET MAGNET (R4 & R5)
TOGGLE SWITCH CONTACTOR 25 OHM 50W
(0) - 24VDC
(1) - 36VDC
(2) - 48VDC
MAGNET
TIMER
UNIVERSAL 24-240 V
MAGNET
NOTE:
CONTROLLER SETTINGS: FOR 36 & 48VDC TUGGER
CALIBRATOR 0.01 = 50% FOR 48V MAGNET WIRED FOR 48V
MAGNET TIMER UNIVERSAL 24-240V
REFERENCE 0.01 = 66% FOR 36V
0.01 = 100% FOR 24V
NOTE:
TITLE:
ELECTRICAL TUGGER 36V, 48V VARIABLE SPEED
40
Electrical Schematic 80V DC (Figure –3.6)
ELECTRICAL TUGGER 80V DC
MOTOR
CONTACTOR
DC
MOTOR MOTOR
24 VDC
15A
EXTENDED
FORWARD
RETRACTED
TIMER CONTACT
MAGNET MAGNET
MAGNET
TIMER
8 or 10 POLE
MAGNET
90V MAGNET
NOTE:
TITLE:
ELECTRICAL TUGGER 80 VDC
41
Battery Tugger Quick Clamp (Figure – 4)
E-BT-QC (Optional Equipment)
Item Qty. Description Part Number

1 1 QUICK CLAMP ASSEMBLY BT-QC-XX-Y
TITLE:
Battery Tugger Quick Clamp
DESIGNED: MJS 04/12/14 CAD File: btmanualdrawings.dwg
42
Battery Tugger Quick Clamp (Optional) (Figure – 4.1)
DWG NO. BT-QC-XX-Y
2
NOTE: XX - 5
-7.5
-13 5
Y - 8,9,10,11,12"
OPTIONAL 3
XX
CBS-2470 TABLE
QTY PART NUMBER
NO. DESCRIPTION Y (LENGTH)
11 CBS-2470-8 1/2-13 UNC THREADED ZINC ROD 8"
PART LIST
ITEM ITEM QTY PART NUMBER DESCRIPTION
BT-801-5 QUICK CLAMP WELDMENT (XX=5" FOR BT-QC-5)
1 1 BT-801-7.5 QUICK CLAMP WELDMENT (XX=7.5" FOR BT-QC-7.5)
BT-801-13 QUICK CLAMP WELDMENT (XX=13" FOR BT-QC-13)
2 1 CBS-2471 3-LOBED HAND WHEEL
3 1 CBS-2470 HREADED ZINC ROD
4 1 CBS-3980 JAMB NUT
5 1 CBS-1512 PLAIN WASHER
DRAWN BY: M.W. Oct. 10 ,2012 FILE NAME: BT-QC-XX-Y QUICK CLAMP ASSEMBLY.dwg
43
Electromagnet Maintenance (Figure – 5)
Electromagnets require very little maintenance to provide a long useful

life. Daily use of a shop towel to wipe the magnet face free of debris,
grease and oil or other foreign matter will ensure years of service life and
thousands of safe operations.
The pulling capacity is greatly reduced when the face of the magnet is
dirty. Use care when handling the magnet so as not to nick or mar the
pulling surface. If the face is heavily worn, lightly surface grind a few
thousandths off the face to clean up the pulling surface.
Never try to remove the electrical wires mounted in the magnet. Should
you do this you will destroy the magnet and it will require rebuilding or
replacement.
BLACK
WHITE
MAGNETIC
POLES
TITLE:
Electromagnet Maintenance
44
Drive Mechanism Maintenance (Figure – 6)
DRIVE CHAIN TENSION ADJUSTMENT
SECTION "A-A"
Item Grease # Of Lubricant Part
Points Point Number
s
1 Drive 3 Spray into container use brush to apply monthly
Chain SCHAEFFERS 200 CBS-3597
2 Bearing 2 ‘Rotanium’ / LOWSON Blue grease or equiualent
2 Months. P-35000 CBS-1208
Cleaner WD-40 (Local purchase)
Antiseize Loctite silver grade (76759) CBS-4236
ATTENTION:
Check monthly and tighten any bolts that have become loose.
Check the drive chain tension. There should be no more than ½” of deflection.
See ‘Drive Chain Tension Adjustment’ inset.
If excessively slack, remove one full link or ½ link and reset tension.
If chain is badly worn or stretched, replace it. TITLE:
Drive Mechanism Maintenance
45
Slider Strip Maintenance (Figure – 7)
The three (3) slider strips (Item 1) on the floor of the “BATTERY
TUGGER” will require regular maintenance to provide long and useful
service (weekly).
Wipe the top of the slider strips to remove debris, grease, oil and any
other foreign material. This will reduce the friction and ensure a long
service life with thousands of safe operations.
If the slider strips are heavily worn, replace them. To do this remove front slider
stop (item 2) and slide the plastic Slider Strip out. Slide the new Slider Strip into
the Slider Strip Channel and replace front slider stop (item 2).
TITLE:
Slider Strip Maintenance
46
Fork Truck Safety Chain (Figure – 8)
Item Qty. Description Part Number

1 60” Safety Chain CBS-527
2 1 Clevis Sling Hook CBS-1019
3 1 Shackle ¼” CBS-1034
Note: Safety Chain will either be side or front mount
TITLE:
Fork Truck Safety Chain
47
Torque Tamer Adjustment
WARNING
To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding.
Failure to observe these precaution could result in bodily injury
20
1. Back off three tension screws #28 . 18 18
16
2. Loosen adjusting nut set screw #26 at least nine turns. 12
3. Tighten adjusting nut assembly #24 hand tight.
4. Tighten adjusting nut set screw #26 in selected spline 22 26
notch. (Do not tighten setscrew on threads of hub.) 14
5. Tighten tension screws #28 alternately and evenly until 24
heads bottom. Do not use washers under heads of
28
these screws.
6. Check alignment of drive. If necessary, loosen hub set
screw #14 and shift hub #12 on shaft.
NOTCH
SPROCKE
T
A shaft would extend from left to right through the bore of the hub #12. A sprocket would be
captured between the two friction discs #20 and this sprocket is free to rotate on the bushing
#22. The hub #12 is keyed to the shaft; therefore any rotational force applied to the sprocket will
be transmitted to the shaft through the friction discs #20 to the pressure plates # 18 which are
splined to the hub #12. The amount of torque transmitted to the shaft depends on how much the
spring #16 is compressed which is determined by the distance between the spring and the
adjusting nut #24. It is important to understand that in order to increase or decrease the amount
of torque transmitted, the adjusting nut #24 must be turned clockwise to increase or counter
clockwise to decrease the torque. See the above instructions for details. Do not try to adjust the
clutch by loosening or tightening the tension screws #28, results will be unpredictable. The only
position these screws should be in when the clutch is in operation is fully bottomed out. Do not
over tighten these bolts, the heads twist off easily.
Item #22 is a sacrificial bushing made of sintered iron. Its purpose is to provide a wear surface
between the sprocket and the hub during the period when the clutch is slipping. The
inexpensive bushing will wear rather than the sprocket or hub. This bushing will, in time, wear
away entirely. This will allow the sprocket to move off center and rotate in an eccentric manner.
If you observe a chain that drives a TORQUE-TAMER™ alternating between very tight and too
loose, the most likely cause is the wearing away of this bushing and it should be replaced
48
Torque Tamer Installation Instructions (Figure – 9)
49

Manual Intercambiador

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Symbol Identification Chart

Do not operate without all Crush Hazard – Keep Hands

Entanglement Hazard – From

Crush Hazard From Falling Crush Hazard – Keep Feet

Eye Protection Required Safety Shoes Required

Heavy Object – Do not exceed

Protective Clothing Required Rubber Gloves Required

Use care when transporting

Eye protection, safety

Fork Truck Front Mounting (Figure – 1b)

Fork Truck Side Mounting (Figure – 1c)

2. Prepare the lift truck for battery removal as follows:

 Lower the forks until they sit flat on the floor.

4. Drive the forklift to an appropriate empty roller stand.

Insertion into the Lift Truck:

FIGURE A1.2 ASSEMBLY

UPDATE: Jan.28, 2013 REV DATE REVISON BY

Drawn By: M.W. Date: Feb 20,2013

* : RECOMMENDED SPARE PARTS

DRAWN BY: M.W. DATE: Aug.13,2013

DRAWN BY: M.W. DATE: Sep.28,2012

104 103 102

24 V STANDARD ELECTRICAL PANEL ASSEMBLY

119 104 111 115 116

DRAWN BY: M.W. DATE: Apr 19,2012

24 V VARIABLE SPEED ELECTRICAL PANEL ASSEMBLY

UPDATE BY: M.W. DATE: Aug.16,2013

24 V JOYSTICK VARIABLE SPEED ELECTRICAL PANEL ASSEMBLY

DRAWN BY: M.W. DATE: Aug.16,2013

115 120 113 103 104 112

UPDATE 27 FEB 2013 DRAWN BY: M.W. DATE: Nov.8,2012

* : RECOMMENDED SPARE PARTS

127 117 113 103 104 112 FILE NAME: BT-24-60-E4(80VDC).dwg

TITLE: JOYSTICK CONTROL ENCLOSURE WITH SOOW CABLE 18-10C

DRAWN BY: MW DATE: Oct.19,2012

NOTE: * : RECOMMENDED SPARE PART 6 10 3

DRAWN BY: MW DATE: SEP.27,2012

* : RECOMMENDED SPARE PART

2 For this Tugger Job#xxxxxx, Y=xx"

DWG TITLE: ALUMINIUM DROP IN ASSEMBLY Y" HIGH

* : RECOMMENDED SPARE PART

For this Tugger Job#xxxxxx, Y=xx"

DWG TITLE: STEEL DROP IN ASSEMBLY Y" HIGH DROP IN

XXXXXX STANDS FOR JOB NUMBER

NOTE: * : RECOMMENDED SPARE PART

For this Tugger Job#

NO.: REVISION DATE:

ELECTRICAL TUGGER 24 V DC STANDARD

ELECTRICAL SCHEMATIC 24V CURTIS CONTROLLER VARIABLE SPEED

ELECTRICAL SCHEMATIC 24V CURTIS CONTROLLER

MAGNET TIMER CONTACT

ELECTRICAL TUGGER 36 OR 48V DC STANDARD

ELECTRICAL SCHEMATIC 36V, 48V

ELECTRICAL TUGGER 80V DC

Item Qty. Description Part Number

Electromagnets require very little maintenance to provide a long useful

DRIVE CHAIN TENSION ADJUSTMENT

Item Qty. Description Part Number

Note: Safety Chain will either be side or front mount

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