PTE 45 901361 - bigjoesupport.com WIRING DIAGRAM (SHEET 1) ... PTE 45 lift truck distributed by Big Joe Manufacturing Company, Des Plaines, Illinois, 60018. Included are

Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901361Rev D 06/18/2008

PTE 45 SERIESSELF-PROPELLED, PALLET

LIFT TRUCK

Operation

Maintenance

Repair Parts List

WARNING

Do not operate this truck unless you have been autho-rized and trained to do so, and have read all warningsand instructions in Operator’s Manual and on thistruck.

Do not operate this truck until you have checked itscondition. Give special attention to tires, horn, battery,controller, lift system, brakes, steering mechanism,guards and safety devices.

Operate truck only from designated operating position.Do not carry passengers. Keep feet clear of truck andwear foot protection.

Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfaces thatcould cause truck to slide or overturn. Use specialcare when traveling without load as the risk of overturnmay be greater.

Always look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with loadtrailing.

Use special care when operating on ramps travelslowly, and do not angle or turn. Travel with liftingmechanism downhill.

Do not handle loads which are higher than the loadbackrest or load backrest extension unless load issecured so that no part of it could fall backward.Before lifting, be sure load is centered, forks are com-pletely under load, and load is as far back as possibleagainst load backrest.

When leaving truck, neutralize travel control, fullylower lifting mechanism and set brake. When leavingtruck unattended, also shut off power.

TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION ............................................................1-11-1. INTRODUCTION..............................................1-11-2. GENERAL DESCRIPTION...............................1-11-3. SAFETY FEATURES. ......................................1-2

2 OPERATION ...............................................................2-12-1. GENERAL. .......................................................2-12-2. OPERATING PRECAUTIONS. ........................2-12-3. BEFORE OPERATION.....................................2-12-4. GENERAL CONTROL OPERATION................2-42-5. DRIVING AND STOPPING PROCEDURES. ...2-42-6. BELLY-BUTTON SWITCH. ..............................2-42-7. STEERING ARM RETURN SPRING. ..............2-52-8. LIFT AND LOWER CONTROLS. .....................2-52-9. LOADING AND UNLOADING. .........................2-52-10. PARKING. ........................................................2-5

3 PLANNED MAINTENANCE ........................................3-13-1. GENERAL. .......................................................3-13-2. MONTHLY AND QUARTERLY CHECKS. .......3-13-3. BATTERY CARE.............................................3-13-4. CHARGING BATTERIES .................................3-13-4.1. REMOVING BATTERIES FROM CHARGER ..3-23-5. LUBRICATION. ................................................3-3

4 TROUBLESHOOTING ................................................4-14-1. GENERAL ........................................................4-14-2. BATTERY CHARGER TROUBLESHOOTING 4-34-2.1. DIP SWITCH SETTING....................................4-34-2.2. THERMISTOR..................................................4-34-2.3. CIRCUIT BREAKER TESTING ........................4-34-2.4. POWER TRANSFORMER TESTING...............4-34-2.5. CIRCUIT BOARD TESTING.............................4-44-3. TRANSISTOR CONTROLLER

TROUBLESHOOTING .....................................4-54-3.1. FAULT DETECTION. .......................................4-54-3.2. HAND HELD PROGRAMMER (OPTIONAL)....4-64-3.3. FAULT RECORDING. ......................................4-64-3.4. FAULT RECOVERY.........................................4-64-3.5. GENERAL CHECKOUT. ..................................4-64-3.6. ADJUSTMENT .................................................4-74-3.7. DIAGNOSTICS AND TROUBLESHOOTING. ..4-74-3.8. PROGRAMMER DIAGNOSTICS .....................4-8

5 STEERING ARM, CONTROL HEAD AND PIVOT SERIVCE.........................................................5-15-1. CONTROL HEAD.............................................5-15-1.1. CONTROL HEAD REMOVAL. .........................5-15-1.2. BELLY-BUTTON SWITCH REPLACEMENT. ..5-15-1.3. LIFT, LOWER AND HORN SWITCH

REPLACEMENT...............................................5-1

5-1.4. DIRECTIONAL SWITCH REMOVAL AND ADJUSTMENT................................................. 5-1

5-1.5. POTENTIOMETER REMOVAL TESTING AND ADJUSTMENT. ....................................... 5-4

5-1.6. CONTROL HEAD INSTALLATION.................. 5-55-2. STEERING ARM ............................................. 5-55-2.1. RETURN SPRING REPLACEMENT. .............. 5-55-3. BATTERY INDICATOR REPLACEMENT........ 5-5

6 BRAKE SERVICING ................................................... 6-16-1. BRAKES. ......................................................... 6-16-1.1. ADJUSTMENT................................................. 6-16-1.2. BRAKE SHOE REPLACEMENT. .................... 6-1

7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL, SKID BAR AND ENTRY/EXIT ROLLER SERVICING 7-17-1. DRIVE WHEEL. ............................................... 7-17-2. TRANSMISSION. ............................................ 7-17-3. LOAD WHEEL. ................................................ 7-17-3.1. REMOVAL ....................................................... 7-17-3.2. REPAIR .......................................................... 7-37-3.3. LOAD WHEEL INSTALLATION....................... 7-37-4. SKID BAR ........................................................ 7-37-5. ENTRY AND EXIT ROLLERS ......................... 7-47-5.1. ENTRY ROLLER REPLACEMENT ................. 7-47-5.2. EXIT ROLLER REPLACEMENT ..................... 7-5

8 ELEVATION SYSTEM SERVICING ........................... 8-18-1. GENERAL........................................................ 8-18-2. LIFT LINKAGE................................................. 8-18-2.1. REMOVAL ....................................................... 8-18-2.2. REASSEMBLY ................................................ 8-18-3. POWER SECTION AND FORK SECTION...... 8-18-3.1. SEPARATING POWER SECTION AND

FORK SECTION. ............................................. 8-18-3.2. FRAME REPAIR. ............................................. 8-28-3.3. CARRIER FRAME REPAIR............................. 8-28-3.4. MATING POWER SECTION AND FORK

SECTION......................................................... 8-2

9 HYDRAULIC SYSTEM SERVICING........................... 9-19-1. LINES AND FITTINGS .................................... 9-19-2. HYDRAULIC PUMP, MOTOR, AND

RESERVOIR ASSY ......................................... 9-29-2.1. REMOVAL ....................................................... 9-29-2.2. DISASSEMBLY AND REASSEMBLY ............. 9-29-2.3. INSTALLATION ............................................... 9-29-2.4. LIFT CYLINDER .............................................. 9-49-2.5. HYDRAULIC PRESSURE ADJUSTMENT ...... 9-4

901361 i

TABLE OF CONTENTS - Continued

Section Page Section Page

10 ELECTRICAL COMPONENTS ................................. 10-110-1. BATTERY AND CHARGER ASSEMBLY ...... 10-110-1.1.BATTERY AND CHARGER ASSEMBLY

REMOVAL ..................................................... 10-110-1.2.BATTERY REMOVAL AND REPLACEMENT10-110-1.3. BATTERY CHARGER .................................. 10-110-1.4.BATTERY AND CHARGER ASSEMBLY

INSTALLATION ............................................. 10-110-2. ELECTRICAL CONTROL PANEL ................. 10-110-2.1.MAINTENANCE............................................. 10-110-2.2.CLEANING .................................................... 10-410-2.3.DIAGNOSTIC HISTORY................................ 10-410-2.4.TEST THE FAULT DETECTION CIRCUITRY10-410-2.5.PANEL REMOVAL. ....................................... 10-410-2.6.PANEL DISASSEMBLY................................. 10-410-2.7.PANEL INSTALLATION. ............................... 10-510-3. HORN REPLACEMENT ................................ 10-510-4. PUMP MOTOR. ............................................. 10-6

10-5. DRIVE MOTOR. .............................................10-610-5.1.BRUSH INSPECTION AND

REPLACEMENT ............................................10-610-5.2.MOTOR REMOVAL .......................................10-710-5.3.MOTOR INSTALLATION ...............................10-710-6. LIFT LIMIT SWITCH.......................................10-710-6.1.REPLACEMENT ............................................10-710-6.2.ADJUSTMENT ...............................................10-710-7. DEADMAN SWITCH ......................................10-710-7.1.REPLACEMENT ............................................10-710-7.2.ADJUSTMENT ...............................................10-7

11 OPTIONAL EQUIPMENT..........................................11-111-1. LOAD BACKREST. ........................................11-111-2. CASTERS ......................................................11-1

12 ILLUSTRATED PARTS BREAKDOWN ....................12-1

LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 NAME PLATE ...................................................... 1-11-2 PTE 45 LIFT TRUCK ........................................... 1-12-1 SAMPLE OF OPERATOR CHECK LIST ............. 2-32-2 FORWARD/REVERSE CONTROL...................... 2-42-3 PUSHBUTTON SWITCHES ................................ 2-42-4 BRAKE ACTUATION ........................................... 2-42-5 BELLY-BUTTON SWITCH................................... 2-53-1 CHARGE INDICATOR ......................................... 3-23-2 LUBRICATION DIAGRAM ................................... 3-44-1 DIP SWITCH SETTINGS ..................................... 4-34-2 BATTERY CHARGER WIRING DIAGRAM.......... 4-44-3 ELECTRICAL PANEL PARTS ............................. 4-54-4 CONTROLLER TERMINALS ............................... 4-64-5 HAND HELD PROGRAMMER............................. 4-74-6 WIRING DIAGRAM (SHEET 1).......................... 4-125-1 CONTROL HEAD SWITCHES............................. 5-25-2 CONTROL HEAD AND STEERING ARM............ 5-35-3 DRIVE CONTROLS ............................................. 5-46-1 DRIVE ASSEMBLY.............................................. 6-26-2 BRAKE ASSEMBLY............................................. 6-27-1 DRIVE ASSEMBLY.............................................. 7-27-2 WHEEL ASSEMBLY ............................................ 7-37-3 ENTRY ROLLERS ............................................... 7-47-4 LEFT EXIT ROLLERS.......................................... 7-57-5 RIGHT EXIT ROLLERS ....................................... 7-58-1 FRAME................................................................. 8-29-1 HYDRAULIC SYSTEM......................................... 9-19-2 HYDRAULIC POWER UNIT ................................ 9-310-1 BATTERY AND CHARGER ASSEMBLY........... 10-2

10-2 BATTERY AND CHARGER ASSEMBLY ...........10-310-3 ELECTRICAL PANEL......................................... 10-510-4 DRIVE MOTOR .................................................. 10-612-1 STEERING ARM ................................................ 12-212-2 CONTROL HEAD ............................................... 12-412-3 CONTROL HEAD ............................................... 12-512-4 DRIVE ASSEMBLY ............................................ 12-612-5 TRANSMISSION ASSEMBLY............................ 12-712-6 DRIVE MOTOR .................................................. 12-812-7 BRAKE ASSEMBLY ........................................... 12-912-8 COMPARTMENT ............................................. 12-1012-9 DECALS ........................................................... 12-1212-10 FRAME ............................................................. 12-1412-11 SKID BAR ASSEMBLY (STANDARD) ............. 12-1612-12 CASTER ASSEMBLY (OPTIONAL) ................. 12-1812-13 LOAD WHEEL ASSEMBLY.............................. 12-2012-14 ENTRY ROLLERS............................................ 12-2112-15 LEFT EXIT ROLLERS ...................................... 12-2212-16 RIGHT EXIT ROLLERS.................................... 12-2312-17 ELECTRICAL PANEL....................................... 12-2412-18 HYDRAULIC SYSTEM ..................................... 12-2512-19 PUMP, MOTOR & RESERVOIR ASSEMBLY.. 12-2612-20 BATTERY INSTALLATION .............................. 12-2812-21 BATTERY AND CHARGER ASSY-

TWO 12V BATTERIES..................................... 12-3012-22 BATTERY AND CHARGER ASSY-

FOUR 6V BATTERIES ..................................... 12-3212-23 BACKREST ...................................................... 12-3412-24 WIRING COMPONENTS ........................ 12-35

ii 901361

LIST OF TABLES

Table Page Table Page

2-1 OPERATOR CHECKS............................................2-23-1 MONTHLY AND QUARTERLY INSPECTION

AND SERVICE CHART ..........................................3-13-2 RECOMMENDED LUBRICANTS ...........................3-33-3 LUBRICATION CHART ..........................................3-4

4-1 TROUBLESHOOTING CHART.............................. 4-14-2 ADJUSTMENT SETTINGS .................................... 4-74-3 LED CODES........................................................... 4-84-4 TROUBLESHOOTING CHART.............................. 4-9

901361 iii

SECTION 1DESCRIPTION

1-1. INTRODUCTION.

This publication describes the 24 volt transistor PTE 45 lift truck distributed by Big Joe ManufacturingCompany, Des Plaines, Illinois, 60018. Included areoperating instructions, planned maintenance instruc-tions, lubrication procedures, corrective maintenanceprocedures and a complete parts list with part locationillustrations.

Users shall comply with all requirements indicated inapplicable OSHA standards and current edition ofA.N.S.I. B56.1 Part II. By following these requirementsand the recommendations contained in this manual,you will receive many years of dependable servicefrom your Big Joe lift truck.

1-2. GENERAL DESCRIPTION.

The self-propelled PTE 45 truck, Figure 1-2, lifts andtransports payloads up to 4500 pounds on rigid forks.

The forward and reverse motion is controlled by eitherof two controller levers mounted on the control head.Stopping and turning is controlled by the steering arm.Lift and Lower is controlled by pushbuttons on the con-trol head. The battery powered lift truck is quiete andwithout exhaust fumes.

The reversible DC motor propels the lift truck in for-ward or reverse direction throughout the availablespeed range. The PTE 45 lift truck can be driven with

forks raised of lowered. The lift truck must be pro-tected from the elements.

The model number will be found on the name plate(Figure 1-1) along with the serial number, lifting capac-ity, and load center. Figure 1-2 shows the locations ofthe truck’s main components and controls.

Figure 1-1 Name Plate

Figure 1-2. PTE 45 Lift Truck

R6209

R6451A

901361 1-1

1-3. SAFETY FEATURES.

The PTE 45 is designed and engineered to providemaximum safety for operator and payload. Some ofthe safety features incorporated into the design are:

• Dead-man brake to apply the brake and cut off drivepower when the steering arm is released.

• Belly-button switch to reverse truck should the oper-ator accidentally pin himself against a wall orobstruction when backing up in slow speed.

• All control functions automatically return to “OFF”when released.

• Externally accessible quick-disconnect battery plugwithin operator's reach.

• Separately fused control circuits and power circuits.

• Readily accessible HORN button.

• Slip-resistance hand to provide a firm hand hold foroperator.

• Flow control valve regulates maximum loweringspeed within prescribed limits.

• Relief valve maintains hydraulic pressure within pre-scribed limits.

• High visibility color scheme of truck provides visualalert of truck’s presence.

• Battery Indicator

• Casters

1-2 901361

SECTION 2OPERATION

2-1. GENERAL.

This section gives detailed operating instructions forthe PTE 45 lift truck. The instructions are divided intothe various phases of operations, such as operatinglift, driving, and stopping. Routine precautions areincluded for safe operation.

2-2. OPERATING PRECAUTIONS.

WARNING: Improper operation of the lift truck mayresult in operator injury, or load and/or lifttruck damage. Observe the followingprecautions when operating the PTE 45lift truck.

The following safety precautions must be adhered toat all times.

• Do not operate this truck unless you have beentrained and authorized to do so and have read allwarnings and instructions in this manual and on thetruck.

• All warnings and instructions must be read andunderstood before using the equipment.

• Equipment must be inspected by a qualified personon a regular basis.

• Do not operate this truck until you have checked itscondition. Give special attention to Tires, Horn, Bat-teries, Controller, Lift System, Brakes, SteeringMechanism, Guards and Safety Devices

• Operate truck only from designated operation posi-tion. Wear foot protection. Do not carry passengers.

• Observe applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is obstructed.

• Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfacesthat could cause truck to slide or overturn. Use spe-cial care when traveling without load as the risk ofoverturn may be greater.

• Always look in direction of travel. Keep a clear view,and when load interferes with visibility, travel withload or lifting mechanism trailing.

• Do not overload truck. Check nameplate for loadweight and load center information.

• Before lifting, be sure load is centered, forks arecompletely under load, and load is as far back aspossible against load backrest.

• Do not handle loads which are higher than the loadbackrest unless load is secured so that no part of itcould fall backward.

• When leaving truck, neutralize travel control. Fullylower lifting mechanism and set brake. When leavingtruck unattended, turn off key switch and disconnectswitch, remove key and disconnect battery.

2-3. BEFORE OPERATION

Table 2-1 covers important inspection points on thePTE 45 lift truck which should be checked prior tooperation. Depending on use, some trucks mayrequire additional checks.

Figure 2-1 shows a sample format for a OperatorChecklist, which can be modified as necessary to fityour operation.

WARNING: Periodic maintenance of this truck by aQUALIFIED TECHNICIAN is required.

CAUTION: A QUALIFIED SERVICE TECHNICIANshould check the truck monthly forproper lubrication, proper fluid levels,brake maintenance, motor maintenanceand other areas specified in the SEC-TION 3.

WARNING: If the truck is found to be unsafe and inneed of repair, or contributes to anunsafe condition, report it immediately tothe designated authority. Do not operateit until it has been restored to a safeoperating condition. Do not make anyunauthorized repairs or adjustments. Allservice must be performed by a qualifiedmaintenance technician.

901361 2-1

Table 2-1 Operator Checks

ITEM PROCEDURETransmission and

hydraulic sys-tems.

Check for signs of fluid leakage.

Forks Check for cracks and damage.Guards and load

backrestCheck that safety guards are in

place, properly secured and not damaged.

Safety signs Check that warning labels, nameplate, etc., are in good condition and legible.

Horn Check that horn sounds when operated.

Steering Check for binding or looseness in steering arm when steering.

Travel controls Check that speed controls on control head operate in all speed ranges in forward and reverse and that belly button switch functions.

Wheels Check drive wheel for cracks or damage. Move truck to check load for freedom of rotation.

Hydraulic controls

Check operation of lift and lower to their maximum positions.

Brakes Check that brakes actuate when steering arm is raised to upright position, and when lowered to horizontal position.

Deadman/Parking brake

Check that steering arm raises to upright position when released and brake applies.

Battery disconnect

Check that battery can be disconnected and recon-nected. Check for connector damage.

Battery charge Check that battery indicator is on “1”.

ITEM PROCEDURE

2-2 901361

Figure 2-1 Sample of Operator Check List

R6479

Electric TruckDaily Operator Check-Off List

Date

Big Joe Manufacturing Company

Operator

Truck No. Model No.

Dept.

Check

Tires

Load Wheels

Horn

Lift Lower Control

Need MaintenanceO.K. ( )

Shift

Hour Meter

Reading Drive Hoist

Attachment Operation

Forward & Reverse Controls

Steering

Brakes

Hydraulic Leaks, Cylinders,

Valves, Hoses, Etc.

901361 2-3

2-4. GENERAL CONTROL OPERATION.

The speed control (See Figure 2-2) located on eachside of the control head provides fingertip control fordriving the truck. Rotate the control in the direction youwant to travel. The farther you rotate the control fromthe neutral position, the faster the truck will travel.

Figure 2-2. Forward/Reverse Control

The pushbutton switches (See Figure 2-3), located onthe front of the control head activate the lift-lower con-trols and the horn.

Figure 2-3. Pushbutton Switches

The brake is fully applied by lowering or raising thesteering arm. (See Figure 2-4) All traction controlpower is shut off when the brake is engaged. Whenthe steering arm is in the upright position, the brakeacts as a parking brake. Deadman braking occurswhen the handle is released and spring action raisessteering arm to the upright position.

Figure 2-4. Brake Actuation

2-5. DRIVING AND STOPPING PROCEDURES.

1. Turn on the key switch and the disconnect switch.Grasp the grips of the steering head so that thespeed control can be comfortably operated byeither thumb.

2. Lower the steering arm to a comfortable positionabove horizontal to disengage the brake and toenergize the electrical circuits. If the truck is notmoved, the electrical circuits will time out and willdeenergize. See Figure 2-4.

3. To move forward (with load in front), slowly pressthe speed control forward. See Figure 2-2. Pressthe forward speed control farther to increasespeed.

4. To slow down or stop, release the speed controland lower or raise the steering arm to the horizon-tal or vertical position. See Figure 2-4. In thosepositions, the brake engages, slowing or stoppingthe truck.

5. Procedures for movement in reverse are thesame as in the forward direction except slowlypress the speed control backward. See Figure 2-2.

2-6. BELLY-BUTTON SWITCH.

The belly-button switch (Figure 2-5) minimizes thepossibility of the driver being pinned by the steeringarm while driving the lift truck in slow speed. If theswitch presses against the operator while the lift truckis being driven toward the operator, the switchchanges the direction of the lift truck.

R6453

R6452

R6454

2-4 901361

Figure 2-5. Belly-Button Switch

2-7. STEERING ARM RETURN SPRING.

The steering arm return spring automatically raises thesteering arm to the upright position when the steeringarm is released. If the steering arm does not returnfully, the steering arm return spring requires replace-ment. Return truck to maintenance for repair.

2-8. LIFT AND LOWER CONTROLS.

Lift/Lower Control buttons are located on the steeringcontrol head. (Figure 2-3)

To lift forks, push in LIFT button and hold until forksreach desired height. To lower forks, push in LOWERbutton and hold until forks descend to desired height.

2-9. LOADING AND UNLOADING.

1. Move truck to location where load is to be pickedup.

2. Move the truck into position so forks are withinpallet or skid, and the load is centered over theforks and as far back as possible.

3. Raise forks to lift load.

4. Drive to area where load is to be placed.

5. Move truck to align load with its new position.

6. Lower the load until it rests squarely in place andthe forks are free.

7. Slowly move the truck out from under the load.

2-10.PARKING.

When finished with moving loads, drive truck to itsmaintenance or storage area. Turn off the disconnectswitch and the key switch. Charge batteries as neces-sary. Refer to battery care instructions, SECTION 3.

R6455

901361 2-5

NOTES

2-6 901361

SECTION 3PLANNED MAINTENANCE

3-1. GENERAL.

Planned maintenance consists of periodic visual andoperational checks, parts inspection, lubrication, andscheduled maintenance designed to prevent or dis-cover malfunctions and defective parts. The operatorperforms the checks in SECTION 2, and refers anyrequired servicing to a qualified maintenance techni-cian who performs the scheduled maintenance andany required servicing.

3-2. MONTHLY AND QUARTERLY CHECKS.

Table 3-1 is a monthly and quarterly inspection andservice chart based on normal usage of equipmenteight hours per day, five days per week. If the lift truckis used in excess of forty hours per week, the fre-quency of inspection and service should be increasedaccordingly. These procedures must be performed bya qualified service technician or your Big Joe servicerepresentative.

3-3. BATTERY CARE.

These batteries are maintenance-free. Any attempt toopen the battery will void the warranty.

Ultra-deep discharging of brand new batteriesshould be avoided for at least 15 cycles. To dramat-ically extend battery life, ultra-deep discharge shouldbe avoided. The shallower the average discharge, thelonger the battery life.

Charge the battery as described in paragraph 3-4.

3-4. CHARGING BATTERIES

Charging requirements will vary depending on depth ofdischarge and temperature. Follow safety rules whenplacing a battery on charge.

Proceed as follows:

1. Park truck at charging station with carriage low-ered and key switch and disconnect switch off.

2. Check the condition of the AC cord, the batteryconnector and battery cables. If there are any cutsin the cable, any exposed wires, loose plugs orconnectors, DO NOT attempt to charge the bat-teries. Contact appropriate personnel for repairsto be made.

Table 3-1 Monthly and Quarterly Inspection and Service Chart

VISUAL CHECKSINTERVAL INSPECTION OR SERVICE

Monthly Check condition of drive motor brushes and springs (Paragraph 10-5.1.).Monthly Check mechanical brake for proper operation.Monthly Check load wheels for wear. A poly load wheel must be replace if worn to within 1/16 inch of

hub. Check for separation from hub.Monthly Check drive wheel for wear. A poly drive wheel must be replace if worn to within 1 inch of

hub. Check for separation from hub.Monthly Check entry and exit wheels for wear or damage.Monthly Inspect wiring for loose connections and damaged insulation.Monthly Inspect contactors for proper operation.Monthly Check deadman brake switch for proper operation.Quarterly Check lift cylinder for leakage.Quarterly Check for excessive jerking of steering arm when stopping or starting.Semi-annually Check brake shoes for wear.

901361 3-1

3. Disconnect the batteries from the truck and con-nect the batteries to the charger. Make sure con-nectors are mated properly.

4. Connect the AC cord to the truck and then pluginto the appropriate power supply.

5. The battery charger is fully automatic and willcycle automatically (depending on amount ofcharge needed). Charge status can be observedas follows (Refer to Figure 3-1):

a. Three LED’s indicate charger status. At startof charge the RED (Charge) LED will be ONindicating the batteries are connected andcharging. After the batteries charge toapproximately 80% the Yellow LED comesON. After a time (1 hour minimum) the GreenLED comes ON indicating battery ready.

NOTE: The battery charger includes an overridetimer which terminates the charge if the cycledoes not complete after 18 hours of charging.This time-out condition is indicated by thegreen LED flashing off and on, and it indi-cates a fault condition which should be inves-tigated. This will occur if the charger cannotraise the battery voltage to the preset voltagelimit. Possible causes indicate a battery fault,a charger fault, low AC power supply voltage,or excessive discharge. The override timercan be reset by switching the AC power to thecharger off.

b. The next four red LED’s indicate current flow.Normally at start of charge, if the batteries

are discharged, all four red LEDs will be onindicating maximum 25A charge current. Asthe batteries charge the current drops andthe LEDs go OFF as the current drops to20A, 15A, 10A and 5A respectively.

3-4.1. Removing Batteries from Charger

1. The Green “READY“ LED stays on until thecharger is unplugged from AC outlet.

2. Disconnect AC plug from the power supply andthen remove it from the truck.

3. Disconnect the batteries from the charger andconnect the batteries to the truck. Make sure con-nectors are mated properly.

Figure 3-1 Charge Indicator

R6114

3-2 901361

3-5. LUBRICATION.

Refer to Table 3-2 for the recommended types ofgrease and oil. Table 3-3 in conjunction with Figure 3-2identifies the items requiring lubrication.

Table 3-2 Recommended Lubricants(See Table 3-3 for Application)

No. 1 Transmission oil—EP SAE 80W-90,Part Number 055780

Transmission oil—EP SAE 10W-30,Part Number 055790 (Note)

No. 2 Grease—Lithium base, general purpose.Part Number 055750Part Number 055753 (Note)

No. 3 Hydraulic oil-Heavy duty with a viscosity of 150 SUS foam suppressing agent and rust and oxidation inhibitorsPart Number 055779

Hydraulic oil-Heavy duty with a viscosity of 100 SUS foam suppressing agent and rust and oxidation inhibitorsPart Number 055784 (Note)

No. 4 SAE 30 or 40 Engine lubricating oilNOTE: USED ON COLD CONDITIONED TRUCKS

901361 3-3

Figure 3-2 Lubrication Diagram

Table 3-3 Lubrication Chart

FIG 3-2 INDEX

NO.

LOCATION METHOD OF APPLICATION

TYPE (Table 3-3)

APPLICATION OF

LUBRICANT1 Transmission

Capacity 2 pintsCan No. 1 Fill to Hex plug (Fill level plug)

level.2 Steering arm pivot Can No. 4 1 or 2 drops each time serviced.3 Pivot Tube Fitting Gun No. 2 Pressure lubricate.4 Hydraulic System

Capacity-6 quartsCan No. 3 With lift carriage fully lowered, fill

reservoir with hydraulic oil to 1 inch below opening.

5 Caster Fittings Gun No. 2 Pressure lubricate.6 Lift Linkage Fittings* Gun No. 2 Pressure lubricate.

* Raise lift carriage to gain access to grease fittings.

R6480

3-4 901361

SECTION 4TROUBLESHOOTING

4-1. GENERAL

Table 4-1 services as a guide to determine possiblecauses of trouble. The table is divided into five maincategories: Truck Dead: Trouble With Travel: Trouble

With Braking: Trouble With Lifting Or Lowering, andMiscellaneous malfunctions. Refer to electrical wiringschematic (Figure 4-6) as a supplement to the trouble-shooting chart or when tracing an electrical circuit.

Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

TRUCK DEADTruck will not run nor will lift sys-

tem operate.a. Fuse (1, Figure 4-3) blown. Check fuse and replace if neces-

sary.

b. Battery dead or disconnected. Check battery quick-disconnect plug and check battery voltage.

c. Keyswitch (9, Figure 12-8) or disconnect switch (10) defective.

Bypass keyswitch to determine if it is malfunctioning. Then bypass disconnect switch to determine if it is malfunctioning.

d. Defective wiring. Check for open circuit. Repair as required.

TROUBLE WITH TRAVELTruck does not run forward or

reverse. All other functions oper-ate normally.

a. Check all wiring. A loose con-nection may be the cause of malfunction.

Tighten all loose connections before further troubleshooting.

b. Defective deadman switch (10, Figure 12-5).

Check and replace switch if defec-tive.

c. Defective main contactor (6, Figure 4-3).

Check for proper operation and replace if necessary.

d. Defective potentiometer (14, Figure 12-3).

Check and replace potentiometer if defective.

e. Transistor control fault may need to be reset.

Move control arm up into the neu-tral position to reset.

Truck runs forward but not in reverse.

Defective reverse switch (6, Fig-ure 12-3) in control head.

Check for proper operation of reverse switch with steering arm in operating position and replace if necessary.

Truck runs reverse but not in for-ward.

Defective forward switch (6, Fig-ure 12-3) in control head.

Check for proper operation of reverse switch with steering arm in operating position and replace if necessary.

Truck runs forward and in reverse at lower speeds; will not run at high speed.

Defective potentiometer (14, Fig-ure 12-3) in control head.

Check for variable resistance at the potentiometer when direction control is activated. If not noted, replace potentiometer.

901361 4-1

Table 4-1 Troubleshooting Chart - Continued


TROUBLE WITH BRAKINGTruck does not slow with brake, or

brake does not engage.a. Defective deadman switch (10,

Figure 12-5).Check deadman switch for conti-

nuity. If none found when the control arm is in the brake posi-tion, replace switch.

b. Defective mechanical brake. Adjust brake or replace brake shoes and drum as necessary.

TROUBLE WITH LIFTING OR LOWERING

Oil sprays or flows from the top of the lift cylinder.

Defective packing in lift cylinder. Replace lift cylinder.

Squealing sounds when lifting forks.

a. Oil level too low. Add oil to reservoir.

b. Lift linkage binding. Apply grease.

Forks do not lift to top. Oil level too low. Add oil to reservoir.

Weak, slow or uneven action of hydraulic system.

a. Defective pump or relief valve. Check pressure. Adjust as neces-sary.

b. Worn lift cylinder. Replace cylinder.

c. Load larger than capacity. Refer to I.D.platefor capacity.

d. Defective lift motor solenoid. Replace solenoid (3, Figure 4-3) on electrical panel.

e. Battery charge low. Charge battery.

Forks do not lift, pump motor does not run.

a. Battery is dead or discon-nected.

Check and recharge if required.

b. Defective wiring. Check and repair as required.

c. Defect in electrical system for operating pump motor.

Check lift switch in control head, as well as the solenoid (3, Figure 4-3) on electrical panel. Replace.

Forks do not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir and the oil lines to the lift cylin-der, and repair as required. If normal, check the hydraulic pump, and relief valve. Repair, or adjust.

Forks lift, but will not go down. Defect in hydraulic system Check lowering control switch (6, Figure 12-3) and lowering sole-noid on valve assembly (3, Fig-ure 12-19). Replace as required.

Load will not hold a. Oil bypassing internally in con-trol valve

Replace valve assembly (3, Fig-ure 12-19).

b. Worn lift cylinder. Replace cylinder.

4-2 901361

4-2. BATTERY CHARGER TROUBLESHOOTING

Refer to Figure 4-2 for part identification. Be sure thebatteries are connected to the charger and the ACcord is connected to 120 VAC power supply.

4-2.1. Dip Switch Setting

The DIP switches (Figure 4-1) on the Printed CircuitBoard (PCB) must be set for Gel Cell Batteries. Checkthat switch 1 is ON and switch 2 is OFF.

Figure 4-1. Dip Switch Settings

4-2.2. Thermistor

There is a temperature sensing thermistor pluggedinto a 2-pin socket marked THERM on the PCB.Check that this is firmly connected or the battery volt-age control will not work properly.

4-2.3. Circuit Breaker Testing

Using a multimeter set to measure 120 VAC, checkeach side of the circuit breaker to ground. If 120 VACwas not indicated on both sides, replace the circuitbreaker.

4-2.4. Power Transformer Testing

The two 0.250” tabs are the primary side of the trans-former. The five #10 screw lugs are the secondaryside. Test the Transformer as follows:

1. Using a multimeter set to measure at least 120VAC, verify that AC Power supply 120 VAC inputis present at the transformer primary terminals. If120 VAC was not indicated, check the circuitbreaker and wiring.

Table 4-1 Troubleshooting Chart - Continued


TROUBLE WITH LIFTING OR LOWERING - Continued

Platform does not lift to top. Pump motor runs.

a. Oil level too low. Add oil to reservoir.

b. Load larger than capacity. Refer to nameplate on side of mast for maximum load capacity.

c. Batteries need charging. Change batteries.

Forks creep downward under load when in a raised position.

Leak in hydraulic system, lift cylin-der or lowering valve.

Check for leaking fitting in hydrau-lic line and repair as required. Replace lift cylinder or valve assembly (3, Figure 12-19).

MISCELLANEOUSSteering arm does not return to

the upright position.a. Week return spring. Replace spring.

b. Binding. Check and free the binding item. Verify that the cable has not been damaged. Repair or replace as needed.

Truck moves forward when arm is pulled down.

a. Belly-button switch defective. Check for short, and repair or replace as necessary.

b. Short in control head. Check wiring and repair as required.

Steering arm jerks excessively starting or stopping the truck.

Drive wheel worn. Replace drive wheel if worn to within 3/8 inch of hub.

Drive motor is jerky. Motor commulator worn. Replace motor.

R6120

901361 4-3

2. Using a multimeter set to measure at least 50VAC, verify the transformer secondary terminalsas follows:

a. Verify 25 VAC from blue wire to each whitewire.

b. Verify 50 VAC from the white wire to whitewire.

c. If these voltages were not indicated, replacethe transformer.

4-2.5. Circuit Board Testing

The circuit board has a built in diagnostic test atpower-up.

1. Switch the AC supply OFF and then ON, watchingthe 3 upper LEDs on the PCB. The 3 LEDs shouldlight briefly in sequence Green-Yellow-Red whenpower is applied. This indicates the transformer isOK and that power is getting to the PCB.

2. If the battery DC is connected to the charger cor-rectly, the Red LED should come ON immediatelyafter this test sequence.

3. If the Green-Yellow-Red LED test sequence doesnot show at power-up, or if it cycles constantlyGreen-Yellow-Red, the PCB assembly should bereplaced.

4. If the Red or Yellow charging LED does not stayON after the test sequence, check that the batter-ies are connected to the charger.

5. Using a multimeter set to measure at least 30VDC, verify DC Voltage from Black to Red wire isas follows:

a. If the Red charging LED is on and the Yellowcharging LED is off, voltage from black to redwire should be at least 24 VDC.

b. If the Red and Yellow charging LEDs are on,voltage should be 29 ±1 VDC.

c. If there is no Voltage, check the wiring andconnections from the charger to the batteryterminals. Battery Voltage must be correctpolarity and more than 1 Volt to commencecharging.

Figure 4-2. Battery Charger Wiring Diagram

R6483

4-4 901361

4-3. TRANSISTOR CONTROLLER TROUBLE-SHOOTING

4-3.1. Fault Detection.

The controller provides diagnostics information toassist technicians in troubleshooting drive systemproblems. When a fault is detected, the appropriatefault code is signaled via the LED, externally visible onthe side of controller (See Figure 4-3 for LED locationon controller). The diagnostic codes flashed by theLED are listed in Table 4-3.

If the fault is critical, the controller is automatically dis-abled. Faults can be caused internally (e.g. shortedtransistors) or externally (e.g., wrench or hardwaredropped across controller terminals).

To recover from a fault, the F/R switch must be turnedoff and back on again. If the fault has been corrected,the controller will turn back on.

The automatic fault detection system includes:

• Contactor coil open / shorted driver

• Contactor driver over-current / contactor coilshort

• Contactor welded

• Emergency reverse circuit check

• M- output fault

• Memory checks upon start-up

• Over-voltage cutback

• Power supply out of range (internal)

• Throttle fault

• Under-voltage cutback

• Watchdog (external and internal)

Figure 4-3. Electrical Panel Parts

R6478

901361 4-5

4-3.2. Hand Held Programmer (Optional)

A hand held programmer is available that is designedspecifically for use with the controller. It serves dualfunctions of reading diagnostic data provided by thecontroller and adjusting certain performance values ofthe controller. The programmer (Part Number005472-02) is available through your Big Joe dealer. Ifyou require dealer location information, contact BigJoe Manufacturing Co. phone number 847-298-9800.

4-3.3. Fault Recording.

Fault events are recorded in the controller's memory.However, multiple occurrences of the same fault arerecorded as one occurrence.

The fault event list can be loaded into the programmerfor readout. The Special Diagnostics mode providesaccess to the controller's diagnostic history file. Thehistory file contains the entire fault event list createdsince the diagnostic history file was last cleared. Thestandard Diagnostics mode provides information aboutonly the currently active faults.

4-3.4. Fault Recovery.

Almost all faults require a cycling of the KSl (KeySwitch Input) or brake input to reset the controller andenable operation. Refer to Table 4-4 for fault clearancerequirements.

4-3.5. General Checkout.

Carefully complete the following checkout procedure.If you find a problem during the checkout, refer toparagraph 4-3.7. for further information.

The checkout can be conducted with or without thehandheld programmer (See Paragraph 4-3.2.). How-ever, the checkout procedure is easier with a program-mer. To evaluate the system without a programmer,observe the LED and note the flashing pattern andrefer to Table 4-3 for the code description.

CAUTION: Put the vehicle up on blocks to get thedrive wheel off the ground before begin-ning these tests.

Turn the keyswitch off and make sure thebrake is applied, the throttle is in neutral,and the forward/reverse switches areopen.

Do not stand, or allow anyone else tostand directly in front of or behind thevehicle during the tests.

1. If a programmer is available, connect it to the pro-grammer connector (Figure 4-4) on the controller.

2. Turn the lift truck key switch to the ON position.The programmer should "power up" with an initialdisplay (2, Figure 4-5), and the controllers StatusLED should begin steadily blinking a single flash.If neither happens, check for continuity in the keyswitch circuit and controller ground.

3. If you are using a programmer, put it into the diag-nostic mode by pressing the "Menu NavigationKey" (1, Figure 4-5). Using the Navigation key,select the Faults menu. Display the Faults menuby pressing the Right side of the Navigation key.Press the Right side of the Navigation key againto display the list of System Faults. The displayshould indicate "No Known Faults."

Release the brake by pulling down the steeringarm into the operating position. The controllersLED should continue blinking a single flash andthe programmer should continue to indicate nofaults. If there is a problem, the LED will flash adiagnostic code and the programmer will display adiagnostic message. If you are conducting thecheckout without a programmer, look up the LEDdiagnostic code in Table 4-3.

When the problem has been corrected, it may benecessary to cycle the brake in order to clear thefault code.

4. With the brake released, select a direction andoperate the throttle. The motor should begin toturn in the selected direction. If it does not, verifythe wiring to the forward/reverse switches andmotor. The motor should run proportionally fasterwith increasing throttle. If not, refer to Paragraph4-3.7.

Figure 4-4. Controller Terminals

R6491

4-6 901361

Figure 4-5. Hand Held Programmer

5. If you are using a programmer, put it into the testmode by using the Navigation key (1) to select the"Monitor" menu. Select the Monitor mode bypressing the "Right" arrow on the Navigation key.Press the Navigation key "Down" arrow to scrolldown to observe the status of the forward,reverse, brake, emergency reverse, and modeswitches. Cycle each switch in turn, observing theprogrammer. Each input should show the correctstate on the programmer.

6. Check the controller's fault detection circuitry asdescribed in Section 10-2.4.

7. Take the vehicle off the blocks and drive it in aclear area. It should have smooth accelerationand good top speed.

8. Test the plug braking of the vehicle. The vehicleshould smoothly slow to a stop and reverse direc-tion, with the audible plugging tone.

9. Verify that all options, such as high pedal disable(HPD), static return to off (SRO), and anti-tie-down, are as desired.

10. Check to see whether the emergency reverse(belly button) feature is working correctly. Verifythat the circuit is operational by momentarily dis-connecting one of the emergency reverse wires.The vehicle should be disabled and a fault indi-cated.

4-3.6. Adjustment

To change a parameter (Table 4-2) using the program-mer, use the Navigation key (1, Figure 4-5) to selectthe "PROGRAM" menu. Press the Right key to displaya listing of program settings. Scroll down the ProgramListing until the desired parameter is highlighted on thedisplay. Press the Right key to display the settings forthe item selected. Press the Increase/Decrease key("+" or "-") (3) until the desired value setting isreached. The parameter is now set at the desiredvalue. All programming occurs in real time. Thatmeans the parameter can be changed while the vehi-cle is in operation.

Some parameters are dependant on other parame-ters. When the programmer is being used to adjust aparameter and a limit is reached, the display will stopchanging.

NOTE: Changing the value of the related parametermay allow the original parameter to beadjusted further.

Table 4-2 Adjustment Settings

4-3.7. Diagnostics and Troubleshooting.

The motor controller provides diagnostics informationto assist in troubleshooting drive system problems.The diagnostics information can be obtained in twoways:

• Reading the appropriate display on the programmer

• Observing the fault codes issued by the Status LED.The Status LED is located on the side of the control-ler. See Figure 4-3 for location of the LED on thecontroller.

+

-

1

2

3

4I-7045

Function Setting

Acceleration Rate (M1 thru M4) 2.0, 2.0, 0.5, 0.5

Braking Current Limit (M1 thru M4) 80, 80, 200, 200

Deceleration Rate (M1 thru M4) 3.0, 3.0, 5.0, 5.0

901361 4-7

4-3.7.1. LED Diagnostics

During normal operation with no faults present, theStatus LED flashes a single flash at approximately 1flash/second. If the controller detects a fault, a 2-digitfault identification code is flashed continuously untilthe fault is corrected. For example, three flashes fol-lowed by two flashes is code "3,2" appears in the LEDcode table as:

000 00 000 00 000 00

(3,2) (3,2) (3,2)

The codes are listed in Table 4-3. The "0" 's in Table4-3 indicate an illuminated LED. For suggestionsabout possible causes of the various faults, refer toTable 4-4 Troubleshooting Chart.

Operational faults, such as an over-temperature situa-tion, are cleared as soon as the operation is broughtwithin range. Non-operational faults, such as a throttlefault, usually requires the brake or key switch to becycled after the problem is remedied.

4-3.8. Programmer Diagnostics

With a programmer, diagnostics and troubleshooting ismore direct than with the LED alone. The programmerpresents complete diagnostic information in plain lan-guage - no code to decipher. Faults are displayed inthe Diagnostic Menu, and the status of the controllerinputs/outputs is displayed in the Test Menu.

The following 4-step process is generally used fordiagnosing and troubleshooting an inoperative vehicleusing the programmer:

1. Visually inspect the vehicle for obvious problems:

2. Diagnose the problem:

3. Test the circuitry with the programmer:

4. Correct the problem.

Repeat the last three steps as necessary until thevehicle is operational.

Refer to the Table 4-4 for suggestions covering awide range of possible faults.

Table 4-3 LED Codes

NOTE: Only one fault is indicated at a time and faults are not queued up.

LED Code Explanation

LED Off Not illuminated No power or defective controller

Solid On Always on Defective controller

Single Flash 0 Controller operational, no faults

1 - 2 0 00 Hardware fail-safe error

1 - 3 0 000 M- fault or motor output short

1 - 4 0 0000 Sequencing fault (SRO)

2 - 1 00 0 Throttle wiper high

2 - 2 00 00 Emergency reverse circuit check fault (BB wiring)

2 - 3 00 000 High-pedal-disable fault (HPD) or expired timer

2 - 4 00 0000 Throttle wiper low

3 - 1 000 0 Contactor driver over current or field winding short

3 - 2 000 00 Welded main contactor

3 - 3 000 000 Field winding open

3 - 4 000 0000 Missing contactor

4 - 1 0000 0 Low battery voltage

4 - 2 0000 00 Overvoltage

4 - 3 0000 000 Thermal cutback, due to over/under temp

4 - 4 0000 0000 anti-tiedown fault, or overheated motor

4-8 901361

Table 4-4 Troubleshooting Chart

LED CODE

PROGRAMMER LCD DISPLAY

POSSIBLE CAUSE FAULT CLEARANCE

0,1 NO KNOWN FAULTS

1,1 CURRENT SHUNT FAULT

1. Abnormal vehicle operation causing high current spikes.

Cycle KSI. If problem persists, replace controller.

2. Current sensor out of range.

3. Controller failure.

1,2 HW FAILSAFE 1. Noisy environment. Cycle KSI. If problem persists, replace controller.

2. Self-test or watchfault.


1,3 M- SHORTED 1. Internal or external short of M- to B-. Check wiring; cycle KSI. If problem persists, replace controller.2. Incorrect motor wiring.


1,4 SRO 1. Improper sequence of KSI, brake, interlock, and direction inputs.

Follow proper sequence; adjust throttle if necessary; adjust programmable parameters if necessary.2. Interlock or direction switch circuit open.

3. Sequencing delay too short.

4. Wrong SRO or throttle type selected.

5. Misadjusted throttle pot.

2,1 THROTTLE WIPER HI 1. Throttle input wire open or shorted to B+. When Throttle Wiper High input returns to valid range.2. Defective throttle pot.

3. Wrong throttle type selected.

2,2 EMR REV WIRING 1. Emergency reverse wire or check wire open. Re-apply emergency reverse or cycle interlock.

2,3 HPD 1. Improper sequence of KSI, interlock, and throttle inputs

Follow proper sequence; adjust throttle if necessary; adjust programmable parameters if necessary.2. Misadjusted throttle pot.

3. Sequencing delay too short.

4. Wrong HPD or throttle type selected.

5. Misadjusted throttle pot.

SRVC TOTAL 1. Total maintenance timer expired. Reset with programmer.

SRVC TRAC 1. Traction maintenance timer expired. Reset with programmer.

TOTAL DISABLED 1. Total disable timer expired. Reset with programmer.

TRAC DISABLED 1. Traction disable timer expired. Reset with programmer.

2,4 THROTTLE WIPER LO 1. Throttle pot wire open or shorted to B+. When Throttle Wiper Low input returns to valid range.2. Wrong throttle type selected.

3. Defective throttle pot.

3,1 FIELD SHORT 1. Main contactor soil shorted. Check contactor soil and field winding; cycle KSI.

2. Field winding shorted to B+ or B-.

3. Field resistance too low.

3,2 MAIN CONT WELDED 1. Main contactor stuck closed. Check wiring and contactor; cycle KSI.

2. Main contactor driver shorted.

3,3 FIELD OPEN 1. Field winding connection open. Check wiring and cycle KSI.

2. Field winding open.

3,4 MISSING CONTACTOR 1. Main contactor coil open. Check wiring and cycle KSI.

2. Main contactor missing.

3.Wire to main contactor open.

901361 4-9

Table 4-5 Troubleshooting Chart - Continued4,1 LOW BATTERY VOLT-

AGE1. Battery voltage < undervoltage cutback. When voltage rises above undervoltage cutoff

point.2. Corroded battery terminal.

3. Loose battery or controller terminal.

4,2 OVERVOLTAGE 1. Battery voltage > overvoltage shutdown limit. When voltage falls below overvoltage cutoff point.

4,3 THERMAL CUTBACK 1. Temperature >85°C or <-25°C. Clears when heatsink temperature returns to within acceptable range.2. Excessive load on vehicle.

3. Improper mounting of controller.

4,4 ANTI-TIEDOWN 1. Mode switches shorted to B+. Release Mode Select 1.

2. Mode Select 1:”tied down” to select Mode 2 or Mode 4 permanently.

MOTOR HOT 1. Field resistance > motor hot setpoint. When resistance < setpoint.

MOTOR WARM 1. Field resistance > motor warm setpoint. When resistance < setpoint.

4-10 901361

NOTES

901361 4-11

Figure 4-6 Wiring Diagram (Sheet 1)

R6490A

4-12 901361

Figure 4-6 Wiring Diagram (Sheet 1)

R6490B

901361 4-13

NOTES

4-14 901361

SECTION 5STEERING ARM, CONTROL HEAD AND PIVOT SERIVCE

5-1. CONTROL HEAD

5-1.1. Control Head Removal.

1. Turn off the key switch (9, Figure 12-8), discon-nect switch (10) and disconnect the batteries.

2. Remove the six outer screws (12, Figure 5-1) andlift off cover (18).

NOTE: The seventh inner screw (14) and nut (13)secure support plate (22) to cover (18).

NOTE: When removing the control head in the fol-lowing step, be sure to hold it in place untilthe control cable is disconnected.

3. Working inside the control head, remove twoscrews (3, Figure 5-2) and two washers (4), beingcareful not to drop control head (1).

4. Lift up control head (1) and unplug the electricalconnector.

5-1.2. Belly-Button Switch Replacement.

1. Remove the control head as described in para-graph 5-1.1.

2. Place the control head on a clean work bench.

3. Trace the belly-button switch leads down to thecontrol head connector and remove the leadsfrom the connector.

4. Remove two screws (7, Figure 5-1) and two screw(8).

5. Lift switch assembly (1) with mounting bracket (6)out of the control head.

6. Remove switch assembly (1) from mountingbracket (6) being careful not to loose springs (4).

7. Pick out potting compound and remove switch (3)from button (1).

8. Position new switch (3) in button (2) and secure inplace with potting compound.

9. Install switch assembly (1) with springs (4) onmounting bracket (6) and check for proper opera-tion.

10. Position switch assembly (1) with mountingbracket (6) in the control head.

11. Install two screws (7) and two screw (8).

12. Install the switch leads in the control head con-nector.

13. Install the control head as described in paragraph5-1.6.

5-1.3. Lift, Lower and Horn Switch Replacement.



3. Trace the leads of the defective switch down tothe control head connector and remove the leadsfrom the connector.

NOTE: When screw (14, Figure 5-1) and nut (22) areremoved, springs (12) will fall out.

4. Use a small clamp to hold plate (22) and cover(18) together. Remove screw (14) and nut (23).Slowly remove the clamp and separate plate (22)from cover (18) being careful not to loose springs(12).

5. Remove the switch assembly (9, 15 or 19) withthe defective switch.

6. Pick out potting compound and remove switchfrom button.

7. Position new switch in button and secure in placewith potting compound.

8. Place switch assemblies (9, 15 and 19) withsprings (12) in position cover (18).

9. Place plate (22) into position and temporarysecure with a clamp. Install nut (23) and screw(14). Then remove the clamp.

10. Check buttons for proper operation.



5-1.4. Directional Switch Removal and Adjust-ment.



3. Remove two screws (11, Figure 5-3) and liftmounting bracket (8) out of the control head.

4. Remove two nuts (10) and two washers (9) fromtwo screws (5).

901361 5-1

5. Remove the two screws (5) with switches (6) andblock (7).

6. Remove the switch leads from the control headconnector.

7. Position the new switches (6) and block (7) onmounting bracket (8) and secure with two screws(5), two washers (9) and two nuts (10).

8. Position mounting bracket (8) in the control headand install two screws (11).

9. Check that rollers on both switches (6) contact thesurface of cam (4) but do not engage the switchesin the neutral position. If required, loosen screw(11) and adjust position of bracket (8) to obtainproper operation.



Figure 5-1. Control Head Switches

R6461A

5-2 901361

Figure 5-2. Control Head and Steering Arm

R6460

901361 5-3

5-1.5. Potentiometer Removal Testing and Adjust-ment.



3. Remove two screws (11, Figure 5-3) and liftmounting bracket (13) out of the control head.

4. Remove gear (12) from potentiometer (14).

5. Remove the potentiometer mounting nut andremove potentiometer (14) from mounting bracket(13).

6. Remove the potentiometer leads from the controlhead connector.

7. Position the new potentiometer (14) on mountingbracket (13) and secure with potentiometermounting nut.

8. Position mounting bracket (13) in the control headand install two screws (11).

9. Set an ohmmeter to the RX1K (1000) scale andconnect across the potentiometer leads.

10. Slowly press the control knob (18) in the forwarddirection until a click indicating forward switch clo-sure is heard and record the ohmmeter reading.

11. Repeat step 10. while pressing control lever inreverse direction. Meter readings should be thesame as for the forward direction (±200 ohms). Ifmeter readings are not the same, adjust positionof bracket (13) as necessary to obtain the samevalues. Adjust the potentiometer again if neces-sary.

12. Install the potentiometer leads in the control headconnector.


Figure 5-3 Drive Controls

R6462

5-4 901361

5-1.6. Control Head Installation.

1. Position control head (1, Figure 5-2) on arm (7)and plug in the electrical connector.

2. Working inside the control head, install twoscrews (3) and two washers (4).

3. Install cover (18, Figure 5-1) and secure with sixscrews (13)

4. Reconnect the batteries and turn on the keyswitch(9, Figure 12-8) and switch (10).

5-2. STEERING ARM

5-2.1. Return Spring Replacement.

The steering arm return spring (18, Figure 5-2) isreplaced while the steering arm (7) is in the uprightposition.


2. Pull the steering arm (7) down to and insert a pinthrough chain (15) to prevent it from retractingback into the steering arm.

3. Slightly raise the steering arm (7) and remove themaster link (16) securing chain (15) to screw (14).

4. Drive out pin (12) and remove cam (11).

5. Remove the electrical cable from steering arm (7)while removing the steering arm.

6. Lay steering arm (7) flat on the ground with chain(15) facing up.

7. Insert a wire through chain (15) and secure to apipe that can be used as a handle.

CAUTION: The following step requires two people.One to pull on the handle to stretch thespring. The second to remove the pininstalled in step 2.

8. While standing on the steering arm, pull up on thepipe and remove the pin installed in step 2. Thenslowly let chain (15) retract back into the steeringarm.

9. Working from the control head end, remove thespring (19) from steering arm (7).

10. Remove tube (19) from spring (19).

11. Inspect chain (15) and replace if necessary.

12. Inspect sheave (8) and replace if necessary.

13. Reassemble in reverse order.

5-3. BATTERY INDICATOR REPLACEMENT.


2. Remove four screws (2) and cover (4).

3. Tag and disconnect electrical leads from indicator(11).

4. Remove two knurled nuts and U-bracket, part ofbattery indicator (11), to release and remove theindicator.

NOTE: Replacement indicator will be furnished withnuts and U-bracket. The original U-bracketmay be reused, if not damaged.

5. Install battery discharge indicator (11) and securewith supplied U-bracket and nuts. If required, trimthe U-bracket legs to proper length.

6. Reconnect electrical leads, as noted duringremoval.

7. Reinstall the cover (4) and screws (2).

8. Reconnect the batteries and turn on the keyswitch(9) and switch (10).

901361 5-5

NOTES

5-6 901361

SECTION 6BRAKE SERVICING

6-1. BRAKES.

6-1.1. Adjustment.




4. Remove four screws (19, Figure 6-1) and cover(18) from transmission (8).

5. Using a strap wrench to hold drum (17), removenut (9).

6. Remove drum (17) and key (10) from drive motor(15).

7. Remove link (25) and free yoke (26) from thelever of brake assembly (16).

8. Remove clip (7, Figure 6-2) from cam (4).

9. Move lever (6) on teeth of cam (4) to adjust thebrakes.

10. Reinstall clip (7) on cam (4).

11. Attach yoke (26, Figure 6-1) to the lever of brakeassembly (16) and secure with link (25).

12. Install key (10) and drum (17) on drive motor (15).

13. Using a strap wrench to hold drum (17), installnut (9).


15. Check if the brake works normally. If not, repeatsteps 5. though 13.

16. Install cover (18, Figure 6-1) on transmission (8)and secure with four screws (19).

17. Install cover (6, Figure 12-8) and screws (5).

18. Install cover (4) and screws (2).

6-1.2. Brake Shoe Replacement.





5. Using a strap wrench to hold drum (17), removenut (9).

6. Remove drum (17) and key (10) from drive motor(15).

7. Remove link (25) and free yoke (26) from thelever of brake assembly (16).

8. Remove springs (1, Figure 6-2) from shoes (2)and remove the shoes from plate (5).

9. Position new shoes (2) on plate (5) and installsprings (1).

10. Attach yoke (26, Figure 6-1) to the lever of brakeassembly (16) and secure with link (25).

11. Install key (10) and drum (17) on drive motor (15).

12. Using a strap wrench to hold drum (17), installnut (9).


14. Check if the brake works normally. If not, adjustthe brake as described in paragraph 6-1.1.


16. Install cover (6, Figure 12-8) and screws (5).

17. Install cover (4) and screws (2).

901361 6-1

Figure 6-1 Drive Assembly

Figure 6-2 Brake Assembly

R6463

R6465

6-2 901361

SECTION 7TRANSMISSION, DRIVE WHEEL, LOAD WHEEL, SKID BAR

AND ENTRY/EXIT ROLLER SERVICING

7-1. Drive Wheel.



3. Loosen but do not remove nut (14, Figure 7-1).

4. Jack up the truck so the drive wheel is off theground; then securely block the truck to preventmovement.

5. Remove the drive wheel (13) from the transmis-sion.

6. Install new drive wheel in reverse order ofremoval.


7-2. Transmission.

NOTE: The transmission does not have any user ser-viceable parts. If the transmission is thecause of travel problems, it will need to bereplaced.

1. Remove the drive wheel as described in para-graph 7-1.

2. Remove the brake as described in paragraph 6-1.2.

3. Remove the motor as described in paragraph 10-5.2.


5. Remove the steering arm as described in para-graph 5-2.

6. Remove all cables from the pivot tube of thetransmission.

7. Jack up the truck so the drive wheel is off theground; then securely block the truck to preventmovement.

NOTE: Support the transmission assembly duringremoval of the mounting hardware.

8. Remove nut (2, Figure 7-1) and washer (3).

9. Slowly lower the transmission out the bottom ofthe frame.

10. If necessary, remove bearings (4 and 5) seal (6)and ring (7).

11. Remove the drive wheel (13) from the transmis-sion by removing nut (14).

12. Install new transmission by reversing steps 1.through 11. above.

7-3. Load Wheel.

7-3.1. Removal

1. Raise forks.


3. Block the drive wheel to prevent the truck fromrolling.

4. Jack up the forks to raise the load wheels off thefloor. Securely block the forks in the raised posi-tion by positioning supports under both fork tips.

NOTE: When pin (5, Figure 7-2) is removed, loadwheel assembly (6) will drop free.

5. Remove screw (6) securing pin (5) and removepin (5) and load wheel assembly (8).

NOTE: Inspect the load wheel assembly. If the loadwheel is worn within 1/8" of the metal sleeve,or is cracked or damaged, replace the entireload wheel and bearing assembly. Big Joerecommends that both load wheel assem-blies be replaced at the same time. Thisensures level and safe operation of the lifttruck.

901361 7-1


R6463

7-2 901361

7-3.2. Repair

1. Remove seals (1, Figure 7-2) and rings (2) fromwheels (4).

2. Remove bearings (3) from wheels (4).

3. Inspect bearings (3) and replace if necessary.

4. Inspect seals (1) and replace if necessary.

5. Reassemble wheel in reverse of disassembly pro-cedure.

7-3.3. Load Wheel Installation

1. Position load wheel assembly (8, Figure 7-2) inwheel fork (9).

2. Install pin (5) and secure with screw (6).

3. Remove blocking from under the truck.

4. Lower the forks.


7-4. SKID BAR

Skid bars are provided for additional stability. Installa-tion of the skid bars are shown in Figure 12-10 andrepair parts as shown in Figure 12-11.

Figure 7-2. Wheel Assembly

R6481

901361 7-3

7-4 901361

7-5. ENTRY AND EXIT ROLLERS

Entry and exit rollers provide smoother transition inand out of the pallets.

7-5.1. Entry Roller Replacement

1. Raise forks.




5. Remove screws (2, Figure 7-3), bracket (4) andspacer (3) from the fork tip.

6. Remove cotter pin (6) and washer (5).

7. Remove pin (7) and roller (5) from bracket (4).

8. Position new roller (4) in bracket (1) and insert pin(7).

9. Install washer (1) and cotter pin (6).

10. Position bracket (4) and spacer (3) in the fork tipand secure with screws (2).


12. Lower the forks.


Figure 7-3 Entry Rollers

R6532

7-5.2. Exit Roller Replacement

1. Raise forks.




5. Remove screw (10, Figure 12-10). Support rod(17) and remove pin (11).

6. Lower the lift linkage to the ground.

7. Remove screws (12, Figure 7-4 or Figure 7-5) androllers (4).

8. If necessary, replace bracket (1) as follows:

a. Remove screws (3), washers (2) and bracket(1) from the fork.

b. Note the position of screws (6 and 7) andremove the screws from the bracket.

c. Install screws (6 and 7) in the new bracketuntil at the position noted during removal.

d. Position the bracket in the fork and securewashers (2) and screws (3).

9. Install rollers (4) and screws (5).

10. Raise the lift linkage into position and install pin(11, Figure 12-10) being sure to align the setscrew hole in the pin with the hole in the fork.

11. Install screw (10).


13. Lower the forks.


Figure 7-4 Left Exit Rollers

Figure 7-5 Right Exit Rollers

R6534

R6533

901361 7-5

NOTES

7-6 901361

SECTION 8ELEVATION SYSTEM SERVICING

8-1. GENERAL.

The elevation system includes the lift linkage, powersection and fork section.

8-2. Lift Linkage

8-2.1. Removal

1. Lift complete truck to height sufficient to permitaccess to lift linkage under forks. Provide blockingunder carrier frame (27, Figure 8-1), the rear offrame (5) and at tips of the forks.


3. Remove screw (10, Figure 8-1) from carrier frame(27) and drive out shaft (22).

4. Remove screw (18). Support rod (17) and removepin (19). Lower the end of rod (17) to the floor.

5. Remove screw (10). Support rod (17) and removepin (11).

6. Remove rod (17) with attached parts from underthe fork.

7. Remove screw (20) from link (23) and remove pin(21) and links (23).

8. Remove bearings (16) from links (23).

9. Remove screw (15) from wheel fork (13) andremove pin (14) and wheel fork (13).

10. Remove bearings (16) from each end of rod (17).

11. Remove the load wheel from wheel fork asdescribed in paragraph 7-3.1.

8-2.2. Reassembly

1. Install the load wheel in wheel fork as described inparagraph 7-3.3.

2. Install bearing (16, Figure 8-1) in the ends of rod(17).

3. Position wheel fork (13) on the end of rod (17) asshown. Secure by installing pin (14) through thelower hole in fork (13). Secure pin (14) with screw(15).

4. Install bearings (16) in links (23).

5. Position rod (17) between the upper hole in links(23) as shown and install pin (21). Secure pin (21)with screw (20).

6. Position rod (17) with attached parts under thefork.

7. Position fork (13) in the fork and install pin (11).Secure pin (11) with screw (10).

8. Raise rod (17) into position and install pin (19)through the frame. Secure Pin (19) with screw(18).

9. Position links (23) on carrier frame (27) and installshaft (22). Secure with screw (10).

10. Remove blocking and lower the truck to theground.


8-3. Power Section and Fork Section

8-3.1. Separating Power Section and Fork Section.

1. Support entire truck on blocking, providing sepa-rate blocks so that frame (5, Figure 8-1) can befully supported when carrier frame (27) isremoved.



4. Remove the lift cylinder as described in para-graph 9-2.4.

5. Remove the drive wheel as described in para-graph 7-1.

6. Remove the brake as described in paragraph 6-1.

7. Remove the motor as described in paragraph 10-5.2.


9. Remove the transmission as described in para-graph 7-2.

10. Attach a suitable hoist to carrier frame (27, Figure8-1).

11. Remove screw (10) from carrier frame (27) andremove shaft (22) on each side of carrier frame(27).

12. Remove screw (24) from each side of carrierframe (27) and remove the carrier frame.

13. Remove screws (24) and links (25) from frame(5).

14. Remove bearings (26) from links (25).

901361 8-1

8-3.2. Frame Repair.

1. Removal of components mounted on frame (12,Figure 8-1) may be necessary to effect repairs/welding, refer to table of contents for identificationof instructions on such components.

2. Inspect frame (5) for broken welds and weld asnecessary.

3. Replace frame (5) if forks have been bentseverely.

8-3.3. Carrier Frame Repair.

1. Repair of the carrier frame (27, Figure 8-1) is lim-ited to chasing damaged threads and welding ofany broken welds.

8-3.4. Mating Power Section and Fork Section.

1. Install bearings (26, Figure 8-1) in links (25).

2. Attach links (25) to frame (5) with screws (24).

3. With suitable hoist, carefully move carrier frame(27) into position and attach links (25) with screws(24).

4. Move links (23) into position on each side of car-rier frame (27) and install shaft (22). Secure shaftwith screw (10).

5. Remove hoist from carrier frame (27).

6. Install the transmission as described in paragraph7-2.


8. Install the motor as described in paragraph 10-5.3.

9. Install the brake as described in paragraph 6-1.

10. Install the drive wheel as described in paragraph7-1.

11. Install the lift cylinder as described in paragraph9-2.4.

12. Install cover (6, Figure 12-8) and four screws (5).

13. Install cover (4) and four screws (2).


15. Remove the blocking from under the truck.

Figure 8-1 Frame

R6469

8-2 901361

SECTION 9HYDRAULIC SYSTEM SERVICING

9-1. LINES AND FITTINGS

WARNING: When forks are raised, pressure exists inthe hydraulic system lines and fittings. Toensure release of pressure, forks mustbe fully lowered and the batteries discon-nected before performing any mainte-nance on the hydraulic system.

NOTE: Leaking hydraulic fittings may be remedied bysimply tightening fittings. If this does not rem-edy the leak, the fittings or line must bereplaced.

1. Lower forks fully.



CAUTION: Hydraulic oil can damage parts. Wipe offany oil immediately. Provide a containerunder the line or fitting before discon-necting.

4. Refer to Figure 9-1 and remove leaking line or fit-ting and replace it with a new line or fitting.

5. Remove elbow (11, Figure 9-2) from the hydraulicreservoir. Check level of hydraulic oil. Hydraulicoil must be one inch below opening. If required,add hydraulic oil to bring to proper level. Usehydraulic oil listed in Table 3-2.

6. Reinstall elbow (11).


8. Operate the lift and lower buttons to refill the cylinder and lines with hydraulic oil.

9. Remove elbow (11, Figure 9-2) from the hydraulicreservoir. Check level of hydraulic oil. Hydraulicoil must be one inch below opening. If required,add hydraulic oil to bring to proper level. Usehydraulic oil listed in Table 3-2.



Figure 9-1 Hydraulic System

R6466

901361 9-1

9-2. HYDRAULIC PUMP, MOTOR, AND RESER-VOIR ASSY

The hydraulic pump/motor assembly can be disas-sembled and repaired. However, a defective pump,valve or motor requires replacement of that compo-nent.

WARNING: When forks are raised. pressure exists inthe hydraulic system lines and fittings. Toensure release of pressure, forks mustbe fully lowered and the batteries discon-nected before performing any mainte-nance on the hydraulic system.

9-2.1. Removal




4. Remove the battery and charger assembly asdescribed in paragraph 10-1.1.

5. Tag and disconnect electrical leads from themotor.

6. Tag and disconnect electrical leads and spikesuppressor from the solenoid (15, Figure 9-2).

NOTE: The reservoir and hose will be filled withhydraulic oil. Place a container under thepump assembly to catch any hydraulic oil.

7. Disconnect hose (3, Figure 9-1) from pump/motorassembly (9).

8. While supporting the pump/motor assembly (9),remove screws (8).

9. Remove the pump/motor assembly (9).

9-2.2. Disassembly and Reassembly

1. Remove the hydraulic pump/motor assembly asdescribed in paragraph 9-2.1.

2. Remove four screws (10, Figure 9-2), washers (9)and reservoir (8).

3. Remove and discard O-ring (4).

4. Remove two screws (6) and two screws (7).

5. Separate pump (5), motor (1), sleeve (2) andvalve (3).

NOTE: Coat new O-ring (4) with hydraulic oil to pre-vent damage during reassembly.

6. Reassemble the hydraulic pump by reversing theabove procedure.

9-2.3. Installation

1. Position the pump/motor assembly (9, Figure 9-1)in the compartment and secure with screws (8).

2. Reconnect hose (6) to pump/motor assembly (9).

3. Reconnect electrical leads and spike suppressorto solenoid (15, Figure 9-2).

4. Reconnect electrical leads to the motor.

5. Fill hydraulic reservoir by removing elbow (11).Use approved Big Joe hydraulic fluid.


7. Reinstall the battery and charger assembly asdescribed in paragraph 10-1.4.


9. Bleed air from the hydraulic system by repeatedlyraising and lowering lift truck until action issmooth.

10. Refill the hydraulic reservoir.


9-2 901361

Figure 9-2 Hydraulic Power Unit

R6467

901361 9-3

9-2.4. Lift Cylinder

NOTE: The lift cylinder does not have any user ser-viceable parts. If the cylinder is defective, itwill need to be replaced.

9-2.4.1.Removal




4. Ensure that hydraulic pressure has been relievedfrom the lift circuit. Disconnect the hydraulic linefrom the lift cylinder.

5. Disconnect hose (3, Figure 9-1) from cylinder (1)and discard O-ring (2).

6. Remove the four screw and two brackets securingthe cylinder to carrier frame (27, Figure 12-10).

WARNING: Frame is heavy. Use care while securingand lifting in order to prevent injury.

7. With suitable hoist, carefully raise frame (5)slightly so the cylinder can be removed.

9-2.4.2.Installation

1. Position the new cylinder (1, Figure 9-1) on carrierframe (27, Figure 12-10). Then lower the frame(5) onto the cylinder.

2. Reconnect the hose (3, Figure 9-1) to cylinder (1)with new O-ring (2).

3. Fill hydraulic reservoir by removing elbow (11,Figure 9-2). Use approved Big Joe hydraulic fluid.






9-2.5. Hydraulic Pressure Adjustment

The relief valve is factory set to open at the rated pres-sure setting for the pump (not to exceed 2,600 psi) andrarely needs adjusting. If you suspect that the reliefvalve is malfunctioning, perform the following proce-dures:

1. Lower forks as far as they will go.

2. Remove four screws (2, Figure 12-8) and cover(4).

3. Disconnect hose (3, Figure 9-1) from pump/motorassembly (9) and connect a pressure gauge ofadequate range (0-3000 psi) in its place.

4. Activate pump motor and observe reading onpressure gauge. If pressure reading is 2,600 psi,the relief valve is functioning properly and doesnot need adjustment. If pressure reading is not2,600 psi, proceed as follows to adjust reliefvalve:

CAUTION: Do not set pressure too high or hydraulicsystem may be damaged. Factory rec-ommended setting of 2,600 psi shouldbe observed. Under no circumstancesshould pressure be set above 2,600 psi,

5. Remove nut to gain access to adjusting bolt. Withpump motor running, observe pressure gaugeand set pressure to 2,600 psi by turning adjustingbolt clockwise to increase pressure or counter-clockwise to decrease pressure.

6. Deactivate pump motor, disconnect pressuregauge, and reconnect hose (3, Figure 9-1).

7. Fill hydraulic reservoir by removing elbow (11,Figure 9-2). Use approved Big Joe hydraulic fluid.





9-4 901361

SECTION 10ELECTRICAL COMPONENTS

10-1.BATTERY AND CHARGER ASSEMBLY

10-1.1.Battery and Charger Assembly Removal

WARNING: Batteries available for the lift truck vary inweight. A suitable hoist and slingarrangement must be used to preventinjury or battery damage.



3. Remove the four screws securing the battery andcharger assembly to the truck.

4. Using a suitable hoist, slowly raise the battery andcharger assembly up and out of the truck.

5. Set the assembly on suitable blocking.

10-1.2.Battery Removal and Replacement

1. Remove the battery and charger assembly asdescribed in paragraph 10-1.

2. Disconnect the cable assemblies from the batter-ies (30).

3. Remove the batteries (30) from battery box (1).

4. Reverse procedure for installation.

10-1.3. Battery Charger

Refer to paragraph 4-2. for troubleshooting proce-dures. Refer to Figure 10-1 for disassembly and partidentification. Be sure the AC cord is connected toproper power supply.

10-1.4.Battery and Charger Assembly Installation

1. Using a suitable hoist, slowly lower the batteryand charger assembly into position.

2. Secure the battery and charger assembly to thetruck with the four screws



10-2.ELECTRICAL CONTROL PANEL

10-2.1.Maintenance

NOTE: Erratic operation of the truck may be causedby defective controller components. Beforeremoving the electrical panel, perform trou-bleshooting procedures per SECTION 4, todetermine corrective action to be taken.

There are no user-serviceable parts inside the control-ler. No attempt should be made to open the controller.Opening the controller may damage it and will void thewarranty.

The controller is programmed at the factory specifi-cally for the truck model on which it is equipped. It isimportant to replace the controller with the correct pre-programmed unit to assure proper performance set-tings intended for that particular truck. See Figure 12-17 for the preprogrammed controller number.

It is recommended that the controller exterior becleaned periodically, and if a handheld programmer isavailable, this periodic cleaning provides a goodopportunity to check the controller’s diagnostic historyfile. It is also recommended that the controller’s faultdetection circuitry be checked whenever the vehicle isserviced.

901361 10-1

Figure 10-1 Battery and Charger Assembly - Two 12V Batteries

R6477

10-2 901361

Figure 10-2 Battery and Charger Assembly - Four 6V Batteries

R6489

901361 10-3

10-2.2.Cleaning


2. Remove cover (4) and four screws (2).

3. Discharge the capacitors in the controller by con-necting a load (such as a contactor coil or a horn)across the controller’s B+ and B- terminals.

4. Remove any dirt or corrosion from the bus bararea. The controller should be wiped clean with amoist rag. Allow it to dry before reconnecting thebattery.

5. Make sure the connections to the bus bars aretight. Use two well insulated wrenches for thistask in order to avoid steering the bus bars.

10-2.3.Diagnostic History

The handheld programmer can be used to access thecontroller's diagnostic history file. When the program-mer is connected to the unit, the error log file is auto-matically uploaded into the handheld programmer.

To see the present status of the unit, use the MenuNavigation Key (1, Figure 4-5) to select:

Faults->System Faults.

To access this log, use the Menu Navigation Key toselect:

Faults->Fault History

The faults are shown as a code and descriptive text. Ifthere are multiple faults, you have to scroll through thelist using the Up and Down Buttons on the Menu Navi-gation Key

The faults may be intermittent faults, faults caused byloose wires, or faults caused by operator errors. Faultssuch as HPD or over-temperature may be caused byoperator habits or by overloading.

After a problem has been diagnosed and corrected,clearing the diagnostic history file is recommended.This allows the controller to accumulate a new file offaults. By checking the new diagnostic history file at alater date, you can quickly determine whether theproblem has been completely fixed.

To clear the diagnostic history file, select:

Faults->Clear Fault History.

You will be asked to confirm your actions. Use the"plus" arrow (+) for yes to clear the menu and the"minus" arrow (-) (3) to cancel your selection and notclear the Fault History.

10-2.4.Test the Fault Detection Circuitry

1. Put the vehicle up on blocks to get the drive wheeloff the ground.

2. Disconnect the battery and make sure the key-switch is in the "OFF" position.

3. Using an inline fuse holder fitted with a 10 ampfuse and alligator clips, connect the controller's Mand B- terminals.

4. Reconnect the battery and turn the key switch tothe "ON" position. Release the brake and applythe throttle. The motor should not operate.

5. Leave the key switch on and remove the in-linefuse wire. The vehicle status should continue toremain off.

6. Cycle the key switch off and on. Release thebrake and apply the throttle. The vehicle shouldnow operate normally.

10-2.5.Panel Removal.



3. Tag and disconnect all electrical wires and cableswhich connect to the control panel (2, Figure 10-3).

4. Remove three screws and remove control panel(2).

10-2.6.Panel Disassembly.

Refer to Figure 10-3 for location and identity of themajor replacement components mounted on the paneland remove defective parts.

NOTE: The main contactor (6) and lift contactor (3)used on this panel are not repairable andmust be replaced if defective.

10-4 901361

10-2.7.Panel Installation.

1. Install the control panel (2, Figure 10-3) andsecure with the three screws.

2. Refer to Figure 10-3 and wiring schematic (Figure4-6) and connect all electrical wires and cables tothe control panel as noted during removal.



10-3.HORN REPLACEMENT



3. Tag and disconnect all electrical connections fromhorn (4, Figure 10-3).

4. Remove the screw, lock washer, washer, horn (4)and mounting spacer.

5. Check the capacitor for damage and replace asnecessary.

6. Install horn (4) with spacer, washer, lock washer,and screw.



Figure 10-3 Electrical Panel

R6478

901361 10-5

10-4.PUMP MOTOR.

The pump motor is replaceable but not repairable.Refer to paragraph 9-2.

10-5.DRIVE MOTOR.

The drive motor exposed surfaces should be cleanedat least once a month to assure proper cooling ofmotor. Use an air hose to blow bust off of motor sur-faces.

10-5.1.Brush Inspection and Replacement

The brushes can be inspected and replaced withoutremoval of the motor. Proceed as follows:





5. Tag the two outer cables connected to the drivemotor; then disconnect these two cables to pro-vide access.

6. Remove two screws (4, Figure 10-4) and shield(5).

7. Loosen the mounting screw on each brush powerlead. Remove spring (15) from brush (16) andremove the brush.

8. Install new brush, reset brush spring and securethe electrical lead.

9. Repeat Steps 7. and 8. for remaining brushes.

10. Reinstall the shield (5) and two screws (4).

11. Reconnect the cables to the drive motor. Makesure to match the cable label to the terminal.

CAUTION: Make sure that wires do not contactsharp edges of any assembly. Vibrationcan cause the insulation to becomedamaged leading to an electrical hazard.


13. Reinstall cover (6, Figure 12-8) and four screws(5).

14. Reinstall cover (4) and four screws (2).


16. Check for proper operation.

Figure 10-4 Drive Motor

R6464

10-6 901361

10-5.2.Motor Removal

1. Remove the brake as described in paragraph 6-1.

2. Note routing of cables to ensure proper installa-tion.

3. Tag the cables connected to the drive motor; thendisconnect these cables from the drive motor.

4. Remove the four screws (20, Figure 12-4) andfour washers (21) securing motor (15) to thetransmission.

5. Remove motor (15) and O-ring (12). Discard theO-ring.

6. Remove nut (9), gear (11), and key (10) from themotor.

10-5.3.Motor Installation

1. Position key (10, Figure 12-4) and gear (11) onthe shaft of motor (15) and secure with nut (9).

2. Install drive motor with new O-ring (12) onto trans-mission. Make sure to align gear (11) with thegear inside the transmission.

3. Reinstall the four screws (20) and four washers(21) to secure the motor to the transmission.

4. Position cables as noted in removal and recon-nect cables to the drive motor. Make sure tomatch the cable label to the terminal.

5. Reinstall the brake as described in paragraph 6-1.

10-6.LIFT LIMIT SWITCH

10-6.1.Replacement

1. Disconnect wiring from the lift limit switch (5, Fig-ure 10-3).

2. Remove the two screws, washers, mounting plateand switch (5) from panel (2).

3. Position the new switch (5) on panel (2) andsecure with the two screws, washers, and mount-ing plate.

4. Adjust the switch as described in paragraph 10-6.2.

10-6.2.Adjustment

1. Raise the forks until switch (5) is aligned with thedetent of mounting plate (7, Figure 12-8).

2. The detent should trigger the lift limit switch andstop the hydraulic pump and motor.

3. If necessary, loosen screws (8) and adjust mount-ing plate (7).

4. Tighten screws (8) and recheck.

10-7.DEADMAN SWITCH

10-7.1.Replacement

1. Disconnect wiring from the deadman switch (10,Figure 12-5).

2. Remove the two screws (11), washers, mountingplate (12) and switch (10) from bracket (7).

3. Position the new switch (7) on bracket (7) andsecure with the two screws (11), washers, andmounting plate (12).

4. Adjust the switch as described in paragraph 10-7.2.

10-7.2.Adjustment

1. Lower the control arm (7, Figure 12-1) until cam(11) contracts the deadman switch (10, Figure 12-5).

2. The cam should trigger the deadman switch and aclick should be heard.

3. If necessary, loosen screws (11) and adjust dead-man switch (10).

4. Tighten screws (11) and recheck.

901361 10-7

NOTES

10-8 901361

SECTION 11OPTIONAL EQUIPMENT

11-1.LOAD BACKREST.

A load backrest is available for addition to the lift truckto allow handling of high loads. Identification ofreplacement parts, are shown in Figure 12-23.

11-2.CASTERS

Casters provide for additional stability. Installation ofthe casters is shown in Figure 12-10 and repair partsas shown in Figure 12-12.

901361 11-1

NOTES

11-2 901361

SECTION 12ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the PTE 45 Lift Truck.

901361 12-1

Figure 12-1 Steering Arm

R6460

12-2 901361

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 — CONTROL HEAD (FIGURE 12-2) REF

2 902062 HANDLE 1

3 902139 SCREW 2

4 902185 WASHER 2

5 902127 SCREW 1

6 902407 PIN 1

7 902039 CONTROL ARM 1

8 902154 SHEAVE 1

9 902149 SHAFT 1

10 902110 RING-SNAP 2

11 902027 CAM 1

12 902097 PIN 1

13 902082 NUT 1

14 902126 SCREW 1

15 902031 CHAIN 1

16 902075 LINK-MASTER 1

17 902096 PIN 1

18 902160 SPRING 1

19 902179 TUBE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-3

Figure 12-2 Control Head

R6461A

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902040 CONTROL HEAD 1

1 902410 . EMERGENCY REVERSE SWITCH ASSY

1

2 902047 . . EMERGENCY REVERSE BUTTON

1

3 902174 . . SWITCH 1

4 902163 . SPRING 4

5 902115 . RUBBER BUMPER 1

6 902173 . SWITCH BRACKET 1

7 902137 . SCREW 2

8 902141 . SCREW 2

9 902411 . LIFT SWITCH ASSY 1

10 902024 . . BUTTON-LIFT 1

11 902174 . . SWITCH 1

12 902164 . SPRING 6

13 902137 . SCREW 6

14 902137 . SCREW 1

15 902412 . HORN SWITCH ASSY 1

16 902174 . . SWITCH 1

17 902023 . . BUTTON-HORN 1

18 902045 . COVER 1

19 902413 . LOWER SWITCH ASSY 1

20 902174 . . SWITCH 1

21 902025 . . BUTTON-LOWER 1

22 902170 . SUPPORT PLATE 1

23 902089 . NUT 1

24 — . CONTROL HEAD (FIGURE 12-3) REF

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-4 901361

Figure 12-3 Control Head

R6462

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— — CONTROL HEAD 1

1 902104 . RACK 1

2 902165 . SPRING 1

3 902166 . SPRING PIN 1

4 902028 . CAM 1

5 902136 . SCREW 2

6 902175 . SWITCH 2

7 902068 . ISOLATE BLOCK 1

8 902078 . MOUNTING BRACKET 1

9 902183 . WASHER 4

10 902090 . NUT 2

11 902141 . SCREW 4

12 902059 . GEAR 1

13 902079 . MOUNTING BRACKET 1

14 902102 . POTENTIOMETER 1

15 902172 . SWITCH BOX 1

16 902056 . FLANGED BEARING 2

17 902029 . CAM SHAFT 1

18 902041 . CONTROL KNOB 2

19 902036 . CONNECTING WASHER 2

20 902046 . COVER 2

21 902167 . SPRING PIN 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-5


R6463

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 902061 GUARD 1

2 902080 NUT 1

3 902181 WASHER 1

4 902004 BEARING 1

5 902005 BEARING 1

6 902144 SEAL 1

7 902109 BACKUP RING 1

8 — TRANSMISSION ASSY(FIGURE 12-5)

REF

9 902091 NUT 2

10 902069 KEY 2

11 902058 GEAR 1

12 902093 O-RING 1

13 902190 WHEEL ASSEMBLY 1

14 902084 NUT 1

15 — MOTOR ASSY (FIGURE 12-6) REF

16 — BRAKE ASSY (FIGURE 12-7) REF

17 902053 DRUM-BRAKE 1

18 902044 COVER 1

19 902132 SCREW 5

20 902131 SCREW 4

21 902182 WASHER 4

22 902013 BOLT 1

23 902161 SPRING 1

24 902106 RETAINER 1

25 902074 LINK 1

26 902194 YOKE ASSEMBLY 1

27 902088 NUT 1

28 902111 ROD 1

29 902015 BRAKE ARM 1

30 902010 BEARING 1

31 902134 SCREW 1

32 902001 ANCHOR 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-6 901361

Figure 12-5 Transmission Assembly

R6476A

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902177 TRANSMISSION ASSEMBLY 1

1 902020 . BUMPER 1

2 902114 . RUBBER BLOCK 1

3 902138 . SCREW 2

4 902186 . WASHER 2

5 902099 . PLATE 1

6 902116 . SCREW 4

7 902014 . BRACKET 1

8 902124 . SCREW 1

9 902021 . BUSHING 2

10 — . SPRAY NOZZLE 2

11 902434 . RING 1

12 902432 . SEAL 1

13 902433 . O-RING 1

14 902435 . BEARING 2

15 — . FIXED SLEEVE 1

16 — . CASE 1

17 902436 . GEAR 1

18 — . COVER 1

19 — . SCREW 14

20 — . BEARING 2

21 — . WASHER 1

22 — . IDLER GEAR 1

23 — . PIN 2

24 — . SCREW 2

25 902171 SWITCH 1

26 — SCREW 2

27 — MOUNTING PLATE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-7

Figure 12-6 Drive Motor

R6464

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902077 DRIVE MOTOR 1

1 — . SCREW 4

2 — . LOCK WASHER 8

3 — . HEAD, COMMUTATOR END 1

4 902141 . SCREW 2

5 — . COVER 1

6 — . NUT 4

7 — . CLIP 4

8 — . WASHER 2

9 — . WASHER 2

10 — . WASHER 2

11 — . WASHER 2

12 — . SCREW 2

13 — . WAVE WASHER 1

14 — . BEARING 2

15 902169 . SPRING, BRUSH 4

16 902018 . BRUSH 4

17 902019 . BRUSH SOCKET 1

18 — . WASHER 4

19 — . LOCK WASHER 4

20 — . SCREW 4

21 — . STATOR 1

22 — . ROTOR 1

23 — . SNAP RING 1

24 — . SEAL 1

25 — . COVER 1

26 — . SCREW 4

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-8 901361

Figure 12-7 Brake Assembly

R6465

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902016 BRAKE ASSEMBLY 1

1 902162 SPRING 2

2 902155 SHOE 1

3 902133 SCREW 2

4 902026 CAM 1

5 902100 PLATE 1

6 902071 LEVER 1

7 902033 CLIP 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-9

Figure 12-8 Compartment

R6474A

12-10 901361

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 902050 DASH 1

2 902143 SCREW 8

3 902156 SPACER 4

4 902048 COVER 1

5 902125 SCREW 4

6 902178 TRANSMISSION COVER 1

7 902101 PLATE-MOUNTING 1

8 902123 SCREW 2

9 902070 KEY SWITCH 1

— 902408 . KET SET A/R

10 902176 SWITCH-DISCONNECT 1

11 902003 BATTERY INDICATOR 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-11

Figure 12-9 Decals

R6485

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 056564 CAUTION DECAL 2

2 056617 FORWARD-REVERSE DECAL 1

3 056499 NO RIDING DECAL 1

4 056613 OPER. INSTR. DECAL 1

5 061334 NAMEPLATE 1

6 066050 DRIVE SCREW 4

7 056632 BIG JOE DECAL 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-12 901361

NOTES

901361 12-13

Figure 12-10 Frame

R6469

12-14 901361

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 902081 NUT 2

2 902032 WASHER 2

3 902135 SCREW 3

4 — ELECTRIC PANEL (FIGURE 12-17)

1

5 — FRAME 1

6 902012 BOLT 2

7 902086 NUT 2

8 902087 NUT 2

9 902192 WHEEL HOUSING, LH 1

10 902120 SCREW 2

11 902147 SHAFT, PIVOT 2

12 — WHEEL ASSY, LOAD (FIGURE 12-13)

REF

13 902193 WHEEL HOUSING, RH 1


15 902119 SCREW 2

16 902011 BEARING 16

17 902112 PULL ROD 2

18 902130 SCREW 2


20 902118 SCREW 2



23 902072 LINK 4

24 902117 SCREW 4

25 902073 LINK 2

26 902034 BEARING 4

27 — CARRIER FRAME 1

28 902133 SCREW 2

29 — SKID BAR ASSEMBLY (STANDARD)(FIGURE 12-11)

REF

30 — CASTER ASSEMBLY (OPTIONAL)(FIGURE 12-12)

REF

31 — SCREW 8

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-15

Figure 12-11 Skid Bar Assembly (Standard)

R6531

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902415 SKID BAR ASSEMBLY 2

1 902416 . BRACKET 1

2 902417 . WEAR BAR 2

3 902418 . WASHER 3

4 902419 . BOLT 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-16 901361

NOTES

901361 12-17

Figure 12-12 Caster Assembly (Optional)

R6486

12-18 901361

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902409 CASTER ASSEMBLY 2

2 902065 . HOUSING 1

3 902098 . PIN-COTTER 1

4 902083 . NUT 3

5 902108 . RING 2

6 902006 . BEARING 2

7 902146 . SEAL 2

8 902066 . HOUSING-WHEEL 1

9 902008 . BEARING 1

10 902085 . NUT 1

11 902189 . WHEEL 1

12 902113 . ROTARY SHAFT 1

13 902157 . SPACER 2

14 902122 . SCREW 2

15 902009 . BEARING 1

16 902022 . BUSHING 1

17 902121 . SCREW 1

18 902082 . NUT 1

19 902168 . SPRING SOCKET 1

20 902159 . SPRING 1

21 902000 . ADJUSTING BOLT 1

22 902060 . GREASE FITTING 1

23 902414 . WASHER 6

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-19

Figure 12-13 Load Wheel Assembly

R6472

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902191 LOAD WHEEL ASSEMBLY 2

1 902145 . SEAL 2

2 902107 . RING 2

3 902118 . SCREW 1

4 902148 . SHAFT 1

5 902007 . BEARING 2

6 902076 . LOAD WHEEL 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-20 901361

Figure 12-14 Entry Rollers

R6532

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902420 ENTRY ROLLER ASSEMBLY 2

1 902199 . WASHER 3

2 902197 . SCREW 2

3 902196 . SPACER 1

4 902195 . BRACKET 1

5 902198 . ROLLER 3

6 — . COTTER PIN 3

7 902200 . SHAFT 3

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-21

Figure 12-15 Left Exit Rollers

R6534

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902421 LEFT EXIT ROLLER ASSEMBY 1

1 902201 . BRACKET 1

2 902203 . WASHER 2

3 902204 . SCREW 2

4 902202 . ROLLER 3

5 902205 . SHOULDER BOLT 3

6 902208 . SCREW 2

7 902207 . SCREW 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-22 901361

Figure 12-16 Right Exit Rollers

R6533

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902422 LEFT EXIT ROLLER ASSEMBY 2

1 902206 . BRACKET 1

2 902203 . WASHER 2

3 902204 . SCREW 2

4 902202 . ROLLER 3

5 902205 . SHOULDER BOLT 3

6 902208 . SCREW 2

7 902207 . SCREW 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-23

Figure 12-17 Electrical Panel

R6478

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 902406 FUSE 1

2 — ELECTRICAL PANEL 1

3 902038 CONTACT, LIFT 1

4 902063 HORN 1

— 902030 CAPACITOR 1

5 902171 SWITCH 1

6 902037 CONTACT, MAIN 1

7 902209 FUSE HOLDER 1

— 902210 FUSE, 10 AMP 1

8 902042 CONTROLLER 1

9 902562 BUS BAR 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

12-24 901361

Figure 12-18 Hydraulic System

R6466

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 902049 CYLINDER, LIFT 1

2 902095 O-RING 1

3 902064 HOSE 1

4 902187 O-RING 1

8 902140 SCREW 4

9 — PUMP, MOTOR & RESERVOIR ASSEMBLY (FIGURE 12-19)

REF

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-25

Figure 12-19 Pump, Motor & Reservoir Assembly

R6467

12-26 901361

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 902103 PUMP, MOTOR & RESERVOIR ASSEMBLY

1

1 902067 . HYDRAULIC PUMP MOTOR 1

2 902035 . CONNECTING BEARING SLEEVE

1

3 902180 . VALVE ASSEMBLY 1

4 902094 . O-RING 1

5 902092 . PUMP 1

6 902128 . SCREW 2

7 902129 . SCREW 2

8 902105 . RESERVOIR 1

9 902184 . WASHER 4

10 902130 . SCREW 4

11 902054 . ELBOW 1

12 902017 . BREATHER 1

15 902055 . ELECTROMAGNETIC COIL

.

.

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-27

Figure 12-20 Battery Installation

R6488

12-28 901361

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 005401 CONNECTOR AND CABLE ASSEMBLY

1

2 077209 WASHER-LOCK, SPLIT, 1/4 6

3 063481 SCREW-HX HD, 1/4-20 X 1-1/5 LG 2

4 402264 SPACER-CONNECTOR, BATT 1

5 077031 WASHER -FLAT, 1/4 4

6 063477 SCREW-HX HD, 1/4-20 X 5/8 LG 4

7 — BATTERY AND CHARGER ASSY (FIGURE 12-21 OR FIGURE 12-22)

REF

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-29

Figure 12-21 Battery and Charger Assy-Two 12V Batteries

R6477

12-30 901361

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 506565 BATTERY BOX WELDMENT 1

2 403688 SPACER - CONNECTOR 1

3 068478 SCREW-SLRH, 1/4-20 X 1-1/4 LG 2


5 059421 NUT-HEX, 1/4-20 2

6 071376 SCREW-PHTH, 10-32 X 1/2 LG 4

7 077207 WASHER-LOCK, SPLIT, #10 4

8 059416 NUT-HEX, #10-32 2

9 506122 CONNECTOR ASSY-CHARGER 1

10 056680 DECAL-CHARGER 1


12 059412 NUT-HEX, #6-32 2

13 005454 CONNECTOR INLET- FLANGED, AC-NON TWIST LOCK

1

13 005461 CONNECTOR INLET- FLANGED, AC, TWIST LOCK

1

14 506567-01 BATT CONNECTOR & CABLE ASSY

1

15 057511 GROMMET 1

16 056113 TIE-HARNESS 5

17 021718 TERMINAL-1/47 SPADE, 16 AWG 4

18 003403 CIRCUIT BREAKER 1

19 506568-01 BATTERY CABLE ASSY 1

20 404992 SPACER-BATTERY, 1/2 X 6 X 6 2

21 055708 ADHESIVE-LIQUID NAILS A/R

22 023010 WIRE-STRANDED, 10 AWG, RED A/R

23 023011 WIRE-STRANDED, 10 AWG, BLACK

A/R

24 023036 WIRE-STRANDED, 10 AWG, WHITE

A/R

25 005471 CONNECTOR-SPLICE, CRIMP, 10 AWG

5


A/R

27 023004 WIRE-STRANDED, 16 AWG, GREEN

A/R


A/R

29 021262 TERMINAL-RING, 10 AWG 7

30 003216 BATTERY-12 VOLT, GMF 2

31 021206 TERMINAL-RING, 1/4 DIA 1

33 403605 SPACER-FOAM, BATTERY 2


35 077210 WASHER-LOCK, SPLIT 5/16 2

36 077030 WASHER-FLAT, #10 2

— 004987 CHARGER KIT-24V, 25A 1

37 904076 . TRANSFORMER 1

38 904075 . CIRCUIT BOARD ASSY 1

39 904074 . THERMISTOR 1

40 055810 CORD-CHARGER-NON TWIST LOCK

1

41 23884 CORD-CHARGER-TWIST LOCK

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-31

Figure 12-22 Battery and Charger Assy-Four 6V Batteries

R6489

12-32 901361

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 506565 BATTERY BOX WELDMENT 1

2 403688 SPACER - CONNECTOR 1

3 068478 SCREW-SLRH, 1/4-20 X 1-1/4 LG 2


5 059421 NUT-HEX, 1/4-20 6

6 071376 SCREW-PHTH, 10-32 X 1/2 LG 2


8 059416 NUT-HEX, #10-32 2

9 506122 CONNECTOR ASSY-CHARGER 1

10 056680 DECAL-CHARGER 1


12 059412 NUT-HEX, #6-32 2

13 005454 CONNECTOR INLET- FLANGED, AC

1

14 506567-02 BATT CONNECTOR & CABLE ASSY

1

15 057511 GROMMET 1

16 056113 TIE-HARNESS 5

17 021718 TERMINAL-1/47 SPADE, 16 AWG 4

18 003403 CIRCUIT BREAKER 1

19 504150-31 CABLE ASSY 1

20 504150-32 CABLE ASSY 1

22 023010 WIRE-STRANDED, 10 AWG, RED A/R


A/R


A/R

25 005471 CONNECTOR-SPLICE, CRIMP, 10 AWG

5


A/R

27 023004 WIRE-STRANDED, 16 AWG, GREEN

A/R


A/R

29 021262 TERMINAL-RING, 10 AWG 7

30 003221 BATTERY-6 VOLT, GMF 4

31 404306 RETAINER-BATTERY 1

32 021206 TERMINAL-RING, 1/4 DIA 1

33 075623-06 STUD-PRESS IN, 1/4-20 X 1.25 2

— 004987 CHARGER KIT-24V, 25A 1

37 904076 . TRANSFORMER 1

38 904075 . CIRCUIT BOARD ASSY 1

39 904074 . THERMISTOR 1

40 055810 CORD-CHARGER 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-33

Figure 12-23 Backrest

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 902002 BACKREST 1

2 902188 WASHER 4

3 902142 SCREW 4

R6475

12-34 901361

Figure 12-24 Wiring Components

R6537

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 902423 CABLE - CONTROLLER A2 TO DRIVE MOTOR A2

1

2 902424 CABLE - CONTROLLER A1 TO DRIVE MOTOR A1

1

3 902425 HARNESS - BATTERY CONNEC-TOR TO FUSE

1

4 902426 HARNESS - BATTERY TO BAT-TERY CONNECTOR

1

5 902427 CABLE - CONTROLLER A1 TO MAIN CONTACTOR

1

6 902428 CABLE - LIFT CONTACTOR TO PUMP MOTOR B2

1

7 902429 CABLE - PUMP MOTOR B- 1

8 902431 HARNESS - CONTROL HEAD TO ELECTRICAL PANEL

1

9 — HARNESS - CONTROL HEAD 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

901361 12-35

NOTES

12-36 901361

Big Joe Manufacturing Company

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