PTW-40 SERIES - Big Lift, LLC Support Site for Big Joe ... · Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901354 REV. A 1104 Manual Price $35.00 PTW-40 SERIES

Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901354REV. A 1104

Manual Price $35.00

PTW-40 SERIESSELF-PROPELLED, PALLET

LIFT TRUCKSerial Number 345621, 345718,

345875 TO 376836

Operation

Maintenance

Repair Parts List

TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION ............................................................1-11-1. INTRODUCTION. ............................................1-11-2. GENERAL DESCRIPTION...............................1-11-3. NAMEPLATE....................................................1-11-4. SAFETY FEATURES. ......................................1-21-5. OPTIONS. ........................................................1-2

2 OPERATION ...............................................................2-12-1. GENERAL. .......................................................2-12-2. OPERATING PRECAUTIONS. ........................2-12-3. GENERAL CONTROL OPERATION................2-12-4. DRIVING AND STOPPING PROCEDURES. ...2-12-5. BELLY-BUTTON SWITCH. ..............................2-32-6. STEERING ARM RETURN SPRING. ..............2-32-7. LIFT AND LOWER CONTROLS. .....................2-32-8. LOADING AND UNLOADING. .........................2-32-9. PARKING. ........................................................2-3

3 MAINTENANCE ..........................................................3-13-1. GENERAL. .......................................................3-13-2. OPERATOR DAILY CHECKS..........................3-13-3. MONTHLY AND QUARTERLY CHECKS. .......3-23-4. BATTERY CARE..............................................3-23-4.1. GENERAL. .......................................................3-23-4.2. BATTERY REMOVAL. .....................................3-23-4.3. TESTING AND CHARGING BATTERY. ..........3-23-5. LUBRICATION. ................................................3-3

4 ADJUSTMENT AND REPAIR .....................................4-14-1. GENERAL. .......................................................4-14-2. PART NUMBER IDENTIFICATION..................4-14-3. STEERING ARM AND CONTROL HEAD. .......4-14-3.1. BELLY-BUTTON SWITCH ADJUSTMENT. .....4-14-3.2. POTENTIOMETER TESTING AND

ADJUSTMENT (TRANSISTOR UNITS ONLY). .............................................................4-1

4-3.3. RESISTOR CONTROL HEAD SWITCH REPLACEMENT...............................................4-2

4-3.4. TRANSISTOR CONTROL HEAD SWITCH REPLACEMENT...............................................4-5

4-3.5. STEERING ARM. .............................................4-64-3.6. ELECTRICAL CONTROL CABLE

REPLACEMENT...............................................4-84-4. BRAKES. ........................................................4-104-4.1. ADJUSTMENT. ..............................................4-104-4.2. REPLACEMENT OF BRAKE PADS...............4-104-4.3. REPLACEMENT OF DEAD-MAN SWITCH. ..4-124-5. TRANSMISSION, DRIVE MOTOR, DRIVE

WHEEL, AND PIVOT TUBE ASSEMBLY. .....4-124-5.1. TRANSMISSION AND PIVOT TUBE

ASSEMBLY REMOVAL..................................4-124-5.2. TRANSMISSION INITIAL DISASSEMBLY.....4-124-5.3. DRIVE AXLE REMOVAL................................4-124-5.4. DRIVE MOTOR/BRAKE ASSEMBLY

REMOVAL. .....................................................4-134-5.5. DRIVE MOTOR SERVICING. ........................4-13

4-6. BASE, FRAME, AND FORK SECTION. ........ 4-174-6.1. GENERAL...................................................... 4-174-6.2. LOAD WHEEL REPLACEMENT. .................. 4-174-6.3. FRAME ASSEMBLY: FORK SECTION

AND LIFT LINKAGE REPAIR AND REPLACEMENT............................................ 4-18

4-7. ELECTRICAL................................................. 4-204-7.1. BATTERY REMOVAL AND REPLACEMENT 4-204-7.2. BATTERY CABLE ASSEMBLIES

REPLACEMENT............................................ 4-204-7.3. RESISTOR/CONTACTOR PANEL. ............... 4-204-7.4. TRANSISTOR/CONTACTOR PANEL -

TRANSISTOR TRUCKS................................ 4-234-7.5. HORN REPLACEMENT. ............................... 4-274-7.6. BATTERY CHARGER (Figure 4-24).............. 4-274-7.7. WIRE HARNESS TESTING. ......................... 4-274-7.8. WIRING. ........................................................ 4-274-8. HYDRAULICS................................................ 4-364-8.1. LINE AND FITTING REPLACEMENT. .......... 4-364-8.2. HYDRAULIC PUMP, MOTOR, AND

RESERVOIR ASSEMBLY. ............................ 4-384-8.3. LIFT CYLINDER REMOVAL.......................... 4-384-8.4. LIFT CYLINDER REPAIR. ............................. 4-394-8.5. HYDRAULIC PRESSURE ADJUSTMENT. ... 4-394-9. DECALS AND TRIM. ..................................... 4-394-9.1. PAINTING REQUIREMENTS........................ 4-394-9.2. DECALS AND PLATES. ................................ 4-39

5 OPTIONS.................................................................... 5-15-1. BATTERY DISCHARGE INDICATOR. ............ 5-15-1.1. BATTERY DISCHARGE INDICATOR

REPLACEMENT.............................................. 5-15-2. HOURMETER.................................................. 5-15-2.1. HOURMETER REPLACEMENT...................... 5-15-3. KEYSWITCH. .................................................. 5-15-4. COLD CONDITIONING PACKAGE................. 5-15-5. LOAD BACKREST........................................... 5-25-6. CASTER .......................................................... 5-2

6 TROUBLESHOOTING................................................ 6-16-1. TROUBLESHOOTING CHART. ...................... 6-16-2. CONTACTOR AND SWITCH

TROUBLESHOOTING..................................... 6-36-2.1. CONTACTOR TESTING. ................................ 6-36-2.2. SWITCH TESTING. ......................................... 6-36-3. TRANSISTOR CONTROLLER

TROUBLESHOOTING..................................... 6-66-3.1. CIRCUIT OPERATION. ................................... 6-66-3.2. GENERAL CHECKOUT (SERIAL NUMBER

373234 TO 376836)......................................... 6-96-3.3. TROUBLESHOOTING (PRIOR TO SERIAL

NUMBER 373234). ........................................ 6-106-3.4. DIAGNOSTICS AND TROUBLESHOOTING

(SERIAL NUMBER 373234 TO 376836). ...... 6-13

PTW1104 i

TABLE OF CONTENTS (Cont)

Section Page Section Page

6-3.5. ADJUSTMENT OF CONTROLLER POTENTIOMETERS (PRIOR TO SERIAL NUMBER 373234). ........................................ 6-15

6-3.6. ADJUSTMENT (SERIAL NUMBER 373234 TO 376836). ...................................... 6-15

6-3.7. MAINTENANCE (SERIAL NUMBER 373234 TO 376836)....................................... 6-16

6-3.8. CLEANING (SERIAL NUMBER 373234 TO 376836) ....................................... 6-16

6-3.9. DIAGNOSTIC HISTORY (SERIAL NUMBER 373234 TO 376836) ....................................... 6-16

6-3.10.TEST THE FAULT DETECTION CIRCUITRY ................................................... 6-16

7 ILLUSTRATED PARTS BREAKDOWN ...................... 7-1

LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 PTW-40 LIFT TRUCK ................................. 1-12-1 STEERING ARM CONTROLS.................... 2-22-2 BRAKE ........................................................ 2-23-1 LUBRICATION DIAGRAM .......................... 3-44-1 BELLY-BUTTON SWITCH AND

POTENTIOMETER ADJUSTMENT ............ 4-24-2 CONTROL HEAD ASSEMBLY -

RESISTOR.................................................. 4-34-3 CONTROL HEAD ASSEMBLY -

TRANSISTOR ............................................. 4-44-4 STEERING ARM......................................... 4-7-5 ELECTRICAL CONTROL CABLE

REPLACEMENT ......................................... 4-94-6 BRAKE ADJUSTMENT............................. 4-104-7 DEAD-MAN SWITCH................................ 4-104-8 BRAKE AND LINKAGE............................. 4-114-9 PIVOT CAP AND TUBE INSTALLATION . 4-134-10 TRANSMISSION ASSEMBLY .................. 4-144-11 DRIVE MOTOR ASSEMBLY .................... 4-154-12 DRIVE MOTOR ASSEMBLY .................... 4-154-13 POWER SECTION FRAME AND

MOTOR COMPARTMENT COVER.......... 4-164-14 FORK SECTION ASSEMBLY ................... 4-174-15 PULL ROD ADJUSTMENT DETAILS ....... 4-194-16 STORAGE BATTERIES AND

CONNECTORS......................................... 4-214-17 ELECTRICAL INSTALLATION -

RESISTOR TRUCKS ................................ 4-214-18 CONTACTOR PANEL ASSEMBLY -

RESISTOR TRUCKS ................................ 4-224-19 ELECTRICAL SYSTEM INSTALLATION -

TRANSISTOR TRUCKS ........................... 4-234-20 CONTACTOR PANEL ASSEMBLY -



TRANSISTOR TRUCKS ........................... 4-26

4-23 HORN INSTALLATION............................. 4-284-24 BATTERY CHARGER INSTALLATION .... 4-284-25 WIRING DIAGRAM -

RESISTOR TRUCKS ................................ 4-304-26 WIRING DIAGRAM -

TRANSISTOR TRUCKS ........................... 4-314-27 WIRING DIAGRAM -

TRANSISTOR TRUCKS ........................... 4-324-28 WIRING DIAGRAM -

TRANSISTOR TRUCKS ........................... 4-344-29 HYDRAULIC SYSTEM INSTALLATION ... 4-364-30 PUMP, MOTOR AND RESERVOIR

ASSEMBLY............................................... 4-374-31 HYDRAULIC SYSTEM INSTALLATION ... 4-386-1 CONTACTOR TESTING............................. 6-46-2 SWITCH TESTING ..................................... 6-56-3 FULL FEATURE ELECTRONIC MOTOR

CONTROLLER............................................ 6-76-4 LOCATION OF ADJUSTMENT POTS ...... 6-157-1 CONTROL HEAD ASSEMBLY,

RESISTOR.................................................. 7-27-2 CONTROL HEAD ASSEMBLY -

TRANSISTOR ............................................. 7-47-3 STEERING ARM......................................... 7-67-4 PIVOT TUBE ASSEMBLY .......................... 7-77-5 BRAKE AND LINKAGE............................... 7-87-6 TRANSMISSION ASSEMBLY .................. 7-107-7 DRIVE MOTOR ASSEMBLY .................... 7-127-8 DRIVE MOTOR ASSEMBLY .................... 7-137-9 BASE AND FRAME .................................. 7-147-10 FORK SECTION ASSEMBLY................... 7-167-11 HYDRAULIC SYSTEM INSTALLATION ... 7-187-12 PUMP, MOTOR AND RESERVOIR

ASSEMBLY............................................... 7-197-13 HYDRAULIC CYLINDER ASSEMBLY...... 7-207-14 STORAGE AND BATTERIES AND

CONNECTOR ........................................... 7-217-15 QUICK DISCONNECT CABLE

INSTALLATION......................................... 7-22

ii PTW1104

LIST OF ILLUSTRATIONS (Cont)

Figure Page Figure Page

7-16 HORN INSTALLATION ............................. 7-237-17 ELECTRICAL INSTALLATION,

RESISTOR ................................................ 7-247-18 ELECTRICAL INSTALLATION,

TRANSISTOR ........................................... 7-257-19 PTW BATTERY CHARGER

INSTALLATION........................................ 7-267-20 CONTACTOR PANEL ASSEMBLY,

RESISTOR ................................................ 7-287-21 CONTACTOR PANEL ASSEMBLY,

TRANSISTOR ........................................... 7-30

7-22 CONTACTOR PANEL ASSEMBLY, E RATED TRANSISTOR........................... 7-32

7-23 CONTACTOR PANEL ASSEMBLY, E RATED TRANSISTOR........................... 7-34

7-24 BATTERY DISCHARGE INDICATOR - OPTION..................................................... 7-36

7-25 KEY SWITCH - OPTION ........................... 7-367-26 COLD CONDITIONING PACKAGE

INSTALLATION - OPTION........................ 7-377-27 HOURMETER INSTALLATION - OPTION 7-387-28 LOAD BACKREST - OPTION ................... 7-397-29 CASTER.................................................... 7-40

LIST OF TABLES

Table Page Table Page

3-1 DAILY CHECKS.............................................3-13-2 MONTHLY AND QUARTERLY INSPECTION

AND SERVICE CHART .................................3-23-3 CHARGE TIME FOR BATTERY CHARGING3-33-4 RECOMMENDED LUBRICANTS ..................3-33-4 LUBRICATION CHART..................................3-4

6-1 CONTROLLER SPECIFICATIONSPRIOR TO SERIAL NUMBER 373234 ..........6-7

6-2 CONTROLLER SPECIFICATIONSSERIAL NUMBER 373234 TO 376836..........6-7

6-3 FAULT RECOVERY EXCEPTIONS. .............6-96-4 LED CODES ................................................6-136-5 TROUBLESHOOTING CHART....................6-146-6 ADJUSTMENT SETTINGS ..........................6-16

PTW1104 iii

NOTES

iv PTW1104

SECTION 1DESCRIPTION

1-1. INTRODUCTION.

This publication describes the PTW 40 lift truck manu-factured by Big Joe Manufacturing Company, DesPlaines, Illinois 60018. Resistor and transistor lifttrucks are covered in this manual, in 24 volt configura-tion. Included are operating instructions, plannedmaintenance instructions, lubrication procedures, cor-rective maintenance procedures and a complete partslist with parts location illustrations.

By following the recommendations contained in thismanual, you will receive many years of dependableservice from your Big Joe lift truck.

1-2. GENERAL DESCRIPTION.

The self-propelled PTW 40 truck, Figure 1-1, lifts andtransports payloads up to 4000 pounds on rigid forks.

The forward and reverse motion is controlled by eitherof two control levers mounted on the control head.Stopping and turning is controlled by the steering arm.Lift and Lower is controlled by pushbuttons located onthe control head. The battery-powered lift truck is quietand without exhaust fumes.

The reversible DC motor propels the lift truck in for-ward or reverse direction throughout the availablespeed range. The PTW lift truck can be driven withforks raised or lowered. The lift truck must be operatedand stored in an area where it will be protected fromthe elements.

1-3. NAMEPLATE.

The nameplate is the key for identifying many of thefeatures of your lift truck. It provides information suchas:

Model number

Serial number

Maximum capacity, load center, and maximum liftheight

If applicable, alternate capacity, load center, andmaximum lift height

Truck weight without battery

Minimum weight of battery

Battery voltage

Refer to Figure 1-1 for serial number locations, if thenameplate becomes lost or illegible.

Figure 1-1. PTW-40 Lift Truck

R5140

PTW1104 1-1

1-4. SAFETY FEATURES.

The PTW is designed and engineered to provide max-imum safety for operator and payload. Some of thesafety features incorporated into the design are:

Deadman brake to apply mechanical brake and cut offdrive power when the steering arm is released.

Belly-button switch to reverse truck should the opera-tor accidentally pin himself against a wall or obstruc-tion when backing 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.

Lift carriage backrest to help stabilize the load.

Readily accessible HORN button.

Slip-resistant hand grips to provide a firm hand hold foroperator.

Flow control valve regulates maximum lowering speedwithin prescribed limits.

Relief valve maintains hydraulic pressure within pre-scribed limits.

High visibility color scheme of truck provides visualalert of trucks presence.

1-5. OPTIONS.

Big Joe offers many options and accessories for thePTW lift truck such as:

Keyswitch

Cold Conditioning

Battery Discharge Indicator

Hourmeter For Motors

Load Backrest Extension

Transistor Drive (speed) Control

1-2 PTW1104

SECTION 2OPERATION

2-1. GENERAL.

This section gives detailed instructions for the PTW 40lift truck. Information is applicable to resistor and tran-sistor trucks, in 24 volt configurations. The instructionsare divided into the various phases of operations, suchas operating lift, driving, and stopping. Routine pre-cautions are included 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 PTW lifttruck.

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

2. Do not operate this truck until you have checkedits condition. Give special attention to Tires, Horn,Battery, Controller, Lift System, Brakes, SteeringMechanism, Guards and Safety Devices.

3. Operate truck only from designated operationposition. Wear foot protection. Do not carry pas-sengers.

4. Observe applicable traffic regulations. Yield rightof way to pedestrians. Slow down and sound hornat cross aisles and wherever vision is obstructed.

5. Start, stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfacesthat could cause truck to slide or overturn. Usespecial care when traveling without load as therisk of overturn may be greater.

6. Always look in direction of travel. Keep a clearview, and when load interferes with visibility, travelwith load or lifting mechanism trailing.

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

8. Do not overload truck. Check capacity plate forload weight and load center information.

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

10. Do not handle loads which are higher than theload backrest unless load is secured so that nopart of it could fall backward.

11. When leaving truck, neutralize travel control. Fullylower lifting mechanism and set brake. Whenleaving truck unattended, disconnect battery.

2-3. GENERAL CONTROL OPERATION.

The speed control (See Figure 2-1) located on eachside of the control head provides fingertip control fordriving the truck. As the lower portion of the speedcontrol is pressed, it closes contacts for first speed inthe forward direction. Pressing the speed control far-ther closes a contact for second speed and farther,third speed. The upper portion of the speed controlgoverns the reverse speeds in the same manner.Pushbutton switches, located behind the belly buttonswitch guard, activate the lift-lower controls and thehorn.

Lowering the steering arm to the horizontal or raisingto the vertical applies the brake. (See Figure 2-2) Alltraction control power is shut off when the brake isengaged. When the steering arm is in the upright posi-tion, the brake acts as a parking brake. Deadmanbraking occurs when the handle is released and springaction raises it to the upright position.

2-4. DRIVING AND STOPPING PROCEDURES.

1. Grasp the grips of the steering arm so that thespeed control can be comfortably operated byeither thumb. If equipped, turn on the key switch.

2. Lower the steering arm to a comfortable positionabove horizontal to disengage the brake and toenergize the electrical circuits.

3. To move forward (with load trailing), slowly pressthe lower portion of the speed control. Press theforward speed control farther to increase speed.Third speed may be cut out by use of the highspeed cut out switch (optional on transistor lifttrucks).

4. To stop, release the speed control and lower thesteering arm to the horizontal position. In thisposition, the brake pads apply pressure to thebrake disc. Lowering the steering arm farther,increases the braking force. The brake may alsobe applied by raising the steering arm to theupright position.

PTW1104 2-1

Figure 2-1. Steering Arm Controls

Figure 2-2. Brake

R5095

R3629

2-2 PTW1104

NOTE: Procedures for movement in reverse are thesame as in the forward direction.

5. To travel in reverse, lower steering arm to a com-fortable position above horizontal and slowlypress upper portion of speed control.

2-5. BELLY-BUTTON SWITCH. (Figure 2-1)

The belly-button switch minimizes the possibility of thedriver being pinned by the steering arm while drivingthe lift truck in slow speed, forward. If the guardpresses against the operator while the lift truck isbeing driven in forward, the guard actuates a switchwhich changes the direction of the lift truck to reversedirection in low speed.

2-6. STEERING ARM RETURN SPRING.

The steering arm return spring automatically raisesthe steering arm to the upright position when thesteering arm is released. If the steering arm snaps upabruptly, or does not return fully, the steering armreturn spring requires adjustment. Return truck tomaintenance for adjustment.

2-7. LIFT AND LOWER CONTROLS.

Lift/Lower Control buttons are located on the steeringcontrol head, behind the belly button switch guard.(Figure 2-1)

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.

2-8. LOADING AND UNLOADING.

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

2. Move truck into position so forks are within palletor skid, and the load is centered over the forksand 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 straight backward, usingthe FORWARD speed control, to remove forksfrom pallet.

2-9. PARKING.

When finished with moving loads, drive truck to itsmaintenance or storage area. If equipped, turn off thekey switch. Disconnect batteries from TO DRIVEreceptacle and connect to the TO CHARGE recepta-cle. Charge batteries as necessary. Refer to batterycare instructions, paragraph 3-4.

PTW1104 2-3

NOTES

2-4 PTW1104

SECTION 3MAINTENANCE

3-1. GENERAL.

Maintenance includes both the operator daily checkprocedures and scheduled maintenance which mustbe performed by a qualified service technician. Anyneeded service found during the operator daily checkor the monthly and quarterly scheduled maintenanceprocedures must be performed by a qualified mainte-nance technician.

3-2. OPERATOR DAILY CHECKS.

Table 3-1 is a check list identifying both visual andoperational checks which must be performed by the

operator on a daily basis to ensure the safety of theequipment. Optional items are noted as such.

WARNING: If the truck is found to be in need ofrepair, unsafe, or contributes to anunsafe condition, report it immediately. Ifduring operation, the truck becomesunsafe, report it immediately. Do notoperate the truck until it has beenrestored to safe operating condition. Donot make any unauthorized repairs oradjustments.

Table 3-1. Daily Checks

VISUAL CHECKS

ITEM PROCEDURE

DAMAGE Check for bent, dented or bro-ken parts.

LEAKS Check drive unit and hydraulic system.

TIRES AND WHEELS

Check drive wheel and load wheels for wear, damage, binding, etc.

FORKS Check for bends and misalign-ment.

CABLES AND HOSES

Check that they are in place and not damaged.

BATTERY Check water level, and vent caps for damage or plugging.

BATTERY CONNECTOR

Check for cracks, burns and for tight connections with truck receptacle.

GUARDS Check load backrest, covers and guards for damage.

SAFETY DEVICES

Check for damaged paint, cracks, or other damage.

FRAME AND SERVICE COVER

Check for bent, dented or bro-ken parts

HORN Check for sounds.

VISUAL CHECKS

ITEM PROCEDURE

STEERING Check for binding or excessive play. Excessive play will be indicated by shifting of the transmission. If excessive play exists, check pivot bush-ings for wear (Paragraph 4-5).

TRAVEL Check all speed ranges, for-ward and reverse. No unusual noise should be present.

HYDRAULIC CONTROLS

Check lift and lower for binding or unusual noises, etc.

BRAKES Check that brake stops truck within a safe distance and works smoothly. Check dead-man brake by releasing han-dle.

HOURMETER If equipped, check for proper operation.

PARKING BRAKE

Holds truck in place.

BATTERY CHARGE

Check that battery discharge indicator (if equipped) is on “full” or specific gravity of bat-tery indicates full charge.

BELLY BUTTON SWITCH

Check for proper operation.

PTW1104 3-1

Table 3-2. Monthly and Quarterly Inspection and Service Chart

3-3. MONTHLY AND QUARTERLY CHECKS.

Table 3-2 is a monthly and quarterly inspection andservice chart based on normal usage of equipmenteight hours per day, five days per week. If the lift truck,is used in excess of forty hours per week, the fre-quency of inspection and service should be increasedaccordingly.

3-4. BATTERY CARE.

WARNING: Hydrogen gas from the batteries canexplode. Do not smoke, use an openflame, or create an arc or sparks in thevicinity of the batteries. Ventilate wellwhen in an enclosed space and whencharging. The batteries contain SULFU-RIC ACID which causes severe burns.Do not get in eyes, on the skin or cloth-ing. In case of contact, flush immediatelyand thoroughly with clean water. Obtainmedical attention when eyes areaffected.

3-4.1. General.

The life of the batteries can be extended by givingthem proper care. Perform a daily check of the batter-ies whether or not the equipment is in daily use. DONOT overcharge the batteries or battery life will beshortened. DO NOT allow batteries to become com-pletely discharged (specific gravity 1.150 or less). Thiswill also greatly shorten battery life.

3-4.2. Battery Removal.

Removal of batteries requires that it be lifted up out ofit's compartment. (Paragraph 4-7.).

3-4.3. Testing and Charging Battery.

Use the following procedure:

1. Obtain a battery hydrometer.

2. Use the hydrometer to check specific gravity ofeach cell.

INTERVAL INSPECTION OR SERVICEMonthly Clean drive motor and check condition of commutator, brushes and springs

(Paragraph 4-5).Monthly Clean pump motor and check condition of commutator, brushes and springs

(Paragraph 4-8).Monthly Check mechanical brake linkage for proper operation.Monthly Check load wheels for wear. A poly load wheel must be replaced if worn to within 1/16 inch

of hub. Check for separation from hub.Monthly Check drive wheel for wear. A poly load wheel must be replaced if worn to within 1/16 inch

of hub. Check for separation from hub.Monthly Inspect wiring for loose connections and damaged insulation.Monthly Inspect contactor tips for excessive pitting and wear.Monthly Check deadman brake switch for proper operation.Quarterly Check lift cylinders for leakage.Quarterly Check for excessive jerking of steering arm when stopping or starting.Quarterly Check brake pads for wear. Both brake pads must be replaced when pad material of either

one is worn to rivet head surface.

3-2 PTW1104

NOTE: Battery specific gravity readings should agreewithin +0.025 from cell to cell. If variation isgreater, the battery may have to be replaced.

CAUTION: Be sure that no cell plates are exposed(not covered by fluid) before charging.Add distilled water sufficient to just covertop of cell plates. DO NOT over fill cells.

CAUTION: Use distilled water. Impurities in tapwater will damage battery plates.

3. Charge batteries in accordance with Table 3-3.

WARNING: Do not service batteries while on charge.Do not connect or disconnect batteryfrom charger while charger is on.

NOTE: A fully charged battery has a specific gravityof 1.260 to 1.275.

4. After charging, check water level in each cellagain. Water level must cover plates but not behigher than the base of the battery cell filler neck.

Table 3-3. Charge Time for Battery Charging

3-5. LUBRICATION.

Refer to Table 3-3 for recommended types of greaseand oil. Table 3-4 in conjunction with Figure 3-1 identi-fies the items requiring periodic lubrication.

Table 3-4. Recommended Lubricants(See Table 3-4 for Application)

SPECIFIC GRAVITY

CHARGE TIME (Hours)15 AMP CHARGER 155 AH BATTERIES

15 AMP CHARGER 200 AH BATTERIES

1.250 2 21.240 3 41.220 4 51.200 7 81.180 8 101.160 10 121.140 12 14

No. 1 Transmission oil—EP SAE 80W-90. Capacity - 1.5 quart. Big Joe No. 055780

(Replace with 055790, 1W-30, if cold con-ditioning option for continuous operation below 32°F is installed).

No. 2 Grease—Lithium base, general purpose. Big Joe No. 055750 (Replace with 055753 if cold conditioning option for continuous operation below 32°F is installed).

No. 3 Hydraulic oil. Big Joe No. 900855 (Gallon) or 900893 (Quart). (Replace with 055784 if cold conditioning option for continuous operation below 32°F is installed).

No. 4 Engine lubricating oil - No. 20

PTW1104 3-3

Table 3-4. Lubrication Chart

Figure 3-1. Lubrication Diagram

TimeInterval

Fig 3-1 Index No.

Location Method of Application

Type (Table 3-4)

Application Of Lubricant

160 Hours 1 Channel Brush No. 2 Accessed through battery compartment. Brush generous amount of lubricant in middle of channel. If rollers squeak, lower forks slightly and apply grease directly to rollers; operate forks up and down a few times to coat forks up and down a few times to coat lift carriage channels.

Semi-Annually

2 Steering Arm Elbow

Can No. 4 1 or 2 drops each time serviced.

Annually 3 Transmission Housing

Can No. 1 Fill to plug level.

Semi-Annually

4 Hydraulic Reservoir

Can No. 3 Lower carriage, fill to 1 inch below elbow tap in reservoir.

40 Hours 5 Lift Linkage Sleeve Bushings

Can No. 4 1 or 2 drops each time serviced. (20 bush-ings)

Semi-Annually

6 Pivot Tube Bushings

Can No. 4 1 or 2 drops each time serviced.

R5141

3-4 PTW1104

SECTION 4ADJUSTMENT AND REPAIR

4-1. GENERAL.

This section contains information and procedures formaintenance of the PTW lift trucks. Maintenanceincludes adjustment, and repair.

This section contains illustrations identifying mainte-nance parts. The callouts on each illustration corre-spond to the reference index numbers in theapplicable text.

Parts listings are provided in SECTION 7 of this man-ual. The part list provides the Big Joe ManufacturingCompany part number, the part description, and thequantity of the part required in the assembly.

When identifying each part to be ordered, visuallycompare the part in the illustration with the actual partneeded. To assure proper identification of each partbeing ordered, include your truck model number, yourtruck serial number (see nameplate), the part numberdescription, and quantity of the part(s) needed. If thenameplate becomes lost or illegible, refer to Figure 1-1for other serial number locations.

4-2. PART NUMBER IDENTIFICATION.

To determine the part number of a replacement part,identify the assembly in which the part is used andlocate the illustration (in SECTION 7) of the applicableassembly. Find the index number for the part on theillustration and refer to that index number in the partslist. If the part number is NP, order the next higherassembly. If the part number is VAR, order by partname with truck model number and serial number.

If the part is listed with more than one part number,select the proper part number by comparing thedescription in the parts list with the specifications ofyour truck. Refer to the nameplate to determine appli-cation to your truck.

4-3. STEERING ARM AND CONTROL HEAD.

4-3.1. Belly-Button Switch Adjustment.

If the actuator gap of the belly-button switch needsadjustment, proceed as follows (Figure 4-1):

1. Disconnect the battery.

2. Drive out the roll pins that secure the belly-buttoncasting (Figure 4-1). Drive from the left to theright.

NOTE: While removing the belly-button casting, thetwo return springs will drop free. Catch thesprings while pulling the casting away to pre-vent their loss. Resistor lift trucks have onebelly-button switch, transistor trucks have astack of three.

3. Bend actuator levers of belly-button switch(es) toadjust gap between rollers and belly-button cast-ing as required (See Figure 4-1).

CAUTION: If too small a gap exists between belly-button switch actuator rollers and thebelly-button casting, the belly-buttonswitch(es) may be actuated constantly.

4. Reinstall belly-button casting, making certain allparts are back in place.

5. Check operation of the belly-button safetyswitch(es) by pressing the belly-button castingwhile listening for the "click" that indicates that theswitch(es) have actuated.

NOTE: The click should be heard when the belly-but-ton casting has moved about 50 percent of itsnormal travel distance. If the click is heard atthe beginning of travel, the switch(es) mayactuate at inappropriate times. If the click isheard near the end of travel, they could beunreliable and may not switch in someinstances.

6. Repeat steps 2. through 5. until pressing thebelly-button casting actuates the switch(es) prop-erly.

7. Reconnect the battery.

WARNING: Testing of belly-button safety switch(es)in operation should be limited to areasclear of obstacles against which an oper-ator could be pinned. Use low speed inforward.

4-3.2. Potentiometer Testing and Adjustment(Transistor Units Only).

1. Disconnect the battery

2. Remove screws (20 and 64, Figure 4-3) andaccess covers (40 and 66).

PTW1104 4-1

Figure 4-1. Belly-Button Switch and Potentiometer Adjustment

3. Check gap between rollers on directional switches(7) and surface of cam (46). If required, adjustposition of bracket (50) to obtain a 0.03 - 0.06 inchclearance.

4. Disconnect the pin and receptacle housingslocated at contactor panel, connecting the controlcable (3, Figure 4-19) and wire harness (39, Fig-ure 4-20, 21, Figure 4-21 or 12, Figure 4-22). Setan ohmmeter to the RX1K (1000) scale and con-nect across pin contacts of wires 4 and 11 at thecontrol cable (3, Figure 4-19) pin housing.

5. Slowly press the control lever (52, Figure 4-3) inthe forward direction until a click indicating for-ward switch closure is heard. Ohmmeter shouldindicate 4550 ± 250 OHMS.

6. If incorrect reading is obtained, use access hole,in side of control head (Figure 4-1) to gain accessto the potentiometer, (3, Figure 4-3). Insert ascrewdriver blade into the slot on the back side ofthe potentiometer (Figure 4-1) and turn slightly.Vary the amount and direction of screwdriver rota-tion until the specified value is achieved.

7. Repeat step 5 while pressing control lever inreverse direction. Meter readings should be thesame as for the forward direction (± 200 OHMS).If meter readings are not the same, adjust positionof bracket (44, Figure 4-3) as necessary to obtainthe same values. Adjust the potentiometer again ifnecessary.

8. Rotate cam (46) in both forward and reversedirections, until it stops. Verify that bypass switch(7) closes in each direction, just prior to the stop.

9. Reassemble the control head.

4-3.3. Resistor Control Head Switch Replacement.


NOTE: Access to belly-button switch (3, Figure 4-2)is provided by removal of safety cover (42);access to other switches is provided byremoval of top cover (54), bottom cover (30),and switch plate (55).

2. Refer to paragraph 4-3.1. if necessary to gainaccess to a defective belly-button switch.

NOTE: Switch operation may be checked with a con-tinuity light containing a battery, or with anohmmeter.

3. Replace a defective belly-button switch (3) as fol-lows:

a. Remove locknuts (7) and screws (19) torelease belly-button switch (3) and insulator(2).

b. Tag and disconnect electrical wires frombelly-button switch (3).

c. Connect electrical wires to new belly-buttonswitch (3), as noted during removal.

R5097

4-2 PTW1104

Figure 4-2. Control Head Assembly - Resistor

R5098

PTW1104 4-3

Figure 4-3. Control Head Assembly - Transistor

R5099

4-4 PTW1104

d. Install insulator (2) and belly-button switch (3)and secure with screws (19) and locknuts (7).

e. Adjust belly-button switch (paragraph 4-3.1.).

4. Replace a defective high speed cutout switch (44)as follows:

a. Disconnect the battery.

b. Remove screws (52) and top cover (54).

c. Remove screws (53) to release cutout switch(44).

d. Tag and disconnect electrical wires from cut-out switch (44).

e. Connect electrical wires to new cutout switch(44), as noted during removal.

f. Install cutout switch (44) and secure withscrews (52).

g. Install top cover (54) and secure with screws(52).

h. Connect battery.

5. Replace a defective pushbutton switch (43 or 45)as follows:



c. Remove screws (13) and bottom cover (30).

d. Remove screws (15 and 16) to release switchplate (55).

e. Remove screws (51) to remove lift or lowerswitch (43).

f. Remove nut and washer from back of hornswitch (45) to remove from switch plate (55).

g. Tag and disconnect electrical wires fromdefective switch.

h. Connect wires to new switch, as noted duringremoval.

i. To install lift or lower switch (43), position onback of switch plate (55) and secure withscrews (51).

j. To install horn switch (45), position on front ofswitch plate (55) and secure with it's washerand nut.

k. Install switch plate (55) and secure withscrews (15 and 16).

l. Install top cover (54) and secure with screws(52).

m. Install bottom cover (30) and secure withscrews (13).

n. Connect the battery.

4-3.4. Transistor Control Head Switch Replace-ment.


NOTE: Access to belly-button switches (5, Figure 4-3) is provided by removal of safety cover (54);access to other switches is provided byremoval of top cover (66), bottom cover (40),and switch plate (67).

2. Refer to paragraph 4-3.1. if necessary to gainaccess to a defective belly-button switch.

NOTE: Switch operation may be checked with a con-tinuity light containing a battery, or with anohmmeter.

3. Replace a defective belly-button switch (5) as fol-lows:

a. Remove locknuts (13) and screws (26) torelease belly-button switches (5) and insula-tor (4).

b. Tag and disconnect electrical wires frombelly-button switches (5).

c. Connect electrical wires to new belly-buttonswitches (5), as noted during removal.

d. Install insulator (4) and belly-button switches(5) and secure with screws (26) and locknuts(13).

e. Adjust belly-button switch (paragraph 4-3.1.).

4. If your unit is equipped with the optional highspeed cutout switch (57), replace it as follows:



c. Remove screws (65) to release cutout switch(57).

d. Tag and disconnect electrical wires from cut-out switch (57).

e. Connect electrical wires to new cutout switch(57), as noted during removal.

f. Install cutout switch (57) and secure withscrews (65).

g. Install top cover (66) and secure with screws(64).

h. Connect battery.

PTW1104 4-5

5. Replace a defective pushbutton switch (56 or 58)as follows:



c. Remove screws (20) and bottom cover (40).

d. Remove screws (22 and 23) to release switchplate (67).

e. Remove screws (63) to remove lift or lowerswitch (56).

f. Remove nut and washer from back of hornswitch (58) to remove from switch plate (67).

g. Tag and disconnect electrical wires fromdefective switch.

h. Connect wires to new switch, as noted duringremoval.

i. To install lift or lower switch (56), position onback of switch plate (67) and secure withscrews (63).

j. To install horn switch (58), position on front ofswitch plate (67) and secure with it's washerand nut.

k. Install switch plate (67) and secure withscrews (22 and 23).

l. Install top cover (66) and secure with screws(64).

m. Install bottom cover (40) and secure withscrews (20).

n. Connect the battery.

6. Replace a defective potentiometer as follows:


b. Remove screws (16, Figure 4-4) to releasethe control head from the steering arm (17).

c. Disconnect flanged connector of wire har-ness assembly (55, Figure 4-3), by unthread-ing the mating connector, and remove thecontrol head.

d. Refer to Figure 4-3 for parts relationship, ifreplacing potentiometer. Tag and disconnectelectrical wires. Carefully note the positionand orientation of all components, to helpensure proper reassembly.

4-3.5. Steering Arm.

1. Steering Arm Return Spring Adjustment (Figure4-4).

The tension on the steering arm return springshould allow the steering arm to return gently tothe upright position. Excessive tension on thesteering arm return spring will cause the steeringarm to snap up and may cause damage to theelectrical cable, brake linkage or the spring itself.If the steering arm does not return fully, first checkfor binding in the brake linkage or wiring harnessbefore making any adjustments. If no binding isfound, then the problem is with the steering armreturn spring. Refer to Figure 4-4 and proceed asfollows to adjust the steering arm return springtension.

CAUTION: The steering arm (17) will have a ten-dency to fall when the tension on thereturn spring (10) is released.

a. Hold the steering arm (17) in upright positionand make sure the arm cannot fall.

b. Insert a 5/16 inch Allen wrench through holein bottom of steering arm (17) and loosenscrew (15). The spring tube (11) will rotatecounterclockwise when screw (15) is loos-ened.

c. With a pair of vise-grip pliers, grip the flat sur-faces of spring tube (11) and rotate clockwise180 degrees.

NOTE: The flat surfaces are on the protruding end ofthe spring tube (11), where the pins (12 and13) are installed.

d. Hold spring tube (11) in rotated position andtighten screw (15) to secure.

e. Check the spring action by lowering thesteering arm (17) and returning it to theupright position two or three times.

f. If necessary repeat steps a through e,increasing or decreasing amount of rotationof the spring tube (11) until steering arm (17)returns gently to full upright position.

2. Replacement (Figure 4-4).

The steering arm return spring (10) is replacedwhile the steering arm (17) is in the upright posi-tion.

a. Disconnect battery.

4-6 PTW1104

b. Remove control head (Paragraph 4-3.4.,above).

CAUTION: The steering arm (17) has a tendency tofall downward when the tension on thereturn spring (10) is released.

c. Hold steering arm (17) and make sure thearm cannot fall.

d. With a piece of chalk or crayon, draw astraight line from center of spring tube (11,Figure 4-4) outward onto pivot cap (4, Figure4-9), marking radial position of tube to facili-tate re-installation.

e. Insert a 5/16-inch Allen wrench through holein bottom of steering arm (17, Figure 4-4).

Loosen and remove screw (15) and spacer(14).

f. Disconnect brake rod (19) from clamp (8).

CAUTION: Unless properly supported, steering arm(17) will drop out of pivot cap (4, Figure4-9) when spring tube (11, Figure 4-4) isremoved.

g. Put a block under steering arm (17) at pivotcap (4, Figure 4-9).

h. With a pair of vise-grip pliers, grip the flat sur-faces of spring tube (11, Figure 4-4) andslowly pull it free from the steering arm (17),pivot cap (4, Figure 4-9) and tube clamp (8,Figure 4-4).

Figure 4-4. Steering Arm

R5100

PTW1104 4-7

NOTE: The flat surfaces are on the protruding end ofthe spring tube (11), where the pins (12 and13) are installed. Steering arm return spring(10) will remain inside the spring tube (11).

i. Remove steering arm return spring (10) fromspring tube (11). If spring is severely jammedand will not come loose, use punch and drivethe 1/4-inch diameter roll pin (13) into thetube. Save pin for re-use. Remove the spring.Tap roll pin back into place.

j. Lubricate the ends and the outer surface ofthe new steering arm return spring (10) witha lithium base general purpose grease.

k. Insert spring (10) into spring tube (11) andpress in, making sure that one spring loopeye fits over the 3/8-inch pin (12) at theclosed end of the spring tube.

l. Slide spring tube (11) into pivot cap (4, Fig-ure 4-9) and steering arm (17, Figure 4-4)through tube clamp (8) and through loop ofelectrical cable. Slowly rotate spring tube afew degrees each way until the steering armreturn spring (10) snaps into place overspring pin (5). Refer to Figure 4-5 for internalview of steering arm with return springinstalled.

m. Connect brake rod (19, Figure 4-4) to clamp(8), securing with new cotter pin (7). Installspacer (14) and screw (15), but do nottighten. Align radial position of spring tube(11) in accordance with line drawn in step e.Tighten screw (15).

n. Remove block from under steering arm.

o. Install control head.

p. Refer to paragraph 4-3.5., step 1, above, and,if necessary, adjust the tension on steeringarm return spring.

q. Reconnect battery.

4-3.6. Electrical Control Cable Replacement.

1. Disconnect battery.

2. Remove 4 screws (11, Figure 4-5) that fasten con-trol head assembly to steering arm.

3. Disconnect the exposed connector (5).

4. Remove cable clamps (1 and 2) and loosen loopof cable that is around the spring tube assembly(3).

5. Remove pivot cap (10).

6. Cut off connector (5) from end of cable.

7. Pull loose end of cable up, and let it extendthrough top of pivot tube (12).

8. Remove screws (3, Figure 4-13), nuts (10), lock-washers (4), flat washers (9), and motor compart-ment (service) cover (1).

9. Disconnect connector (7, Figure 4-5).

10. Refer to Figure 4-17 for resistor trucks, or Figure4-19 for transistor trucks. Remove wire tires andclamps (5), as required to free control cable (3).Note routing of cable, and position of wire ties andcable clamps, to ensure proper installation.

11. Using a suitable pin removal tool, tag and removedead-man switch cable leads from pin locations13 and 14 in connector (7, Figure 4-5).

12. Using a suitable pin removal tool, remove wiresfrom pin locations 1 through 12 in connector (7)on the new replacement control cable.

13. Tape the cut end of the old cable to the wires justremoved from connector (7) on the new cable.

14. Grease the new cable with a lithium base greaseor silicone spray.

15. Draw new cable into pivot tube (12) by pulling oldcable out through opening in transmission hous-ing.

16. Secure connector (5) end of new cable, to preventit from falling in pivot tube (12).

17. Remove old cable from new cable and wipe offexcess grease.

18. Insert wires 1 through 12 into pin locations 1through 12, respectively, in connector (7).

19. Insert dead-man switch cable leads into pin loca-tions 13 and 14 in connector (7), as noted duringremoval.

20. Route new control cable, as noted duringremoval.

21. Group all cables coming from drive motor, dead-man switch and control cable, and clamp asshown on Figure 4-17 or Figure 4-19.

22. Secure cables to transmission housing and powersection frame with clamps (5) and associatedhardware. Use wire ties to bundle cables andwires as noted during removal.

23. Connect connector (7, Figure 4-5).

24. Using a suitable pin removal tool, remove wiresfrom pin locations 1 through 12 in connector (5).Tape the wire ends together.

4-8 PTW1104

25. Pull the connectorless end of cable (4) over pin(14) and under spring tube assembly (3).

26. Eliminate excess cable slack in pivot tube (12);then secure cable with cable clamp (1).

27. Loop cable around spring tube assembly as illus-trated (Figure 4-5) and push connector end ofcable into steering arm.

CAUTION: Improper cable loop adjustment willdamage cable. If too tight, cable will tearwhen steering arm is in up position. If tooloose, cable will buckle or be pinchedwhen steering arm is in down position.

28. Pull the cable until it is wrapped firmly around thespring tube assembly (3). Slack off approximately1/2 inch and secure the cable in this position withcable clamp (2).

29. Work steering arm up and down a few times toassure that the electrical control cable is not bind-ing.

30. Pivot transmission through entire turning range,observing that all electrical cables and wire leadswill flex properly and not become caught orpinched at any time.

31. Reinstall wires 1 through 12 into pin locations 1through 12, respectively in connector (5).

32. Reinstall the control head assembly, engagingconnector (5) to end of speed control harness (3,Figure 4-17 or Figure 4-19) and secure withscrews (7, Figure 4-5).

33. Install pivot cap (10).

34. Install motor compartment (service) cover (1, Fig-ure 4-13) and secure with flat washers (9), lock-washers (4), nuts (11), and screws (3).

35. Connect the battery.

Figure 4-5. Electrical Control Cable Replacement

R5101

PTW1104 4-9

4-4. BRAKES.

4-4.1. Adjustment.

Adjust the brake if it does not engage when the steer-ing arm is raised to within 15 degrees from its parkposition or lowered to within 15 degrees from its lowestposition (Figure 2-2). Proceed as follows:


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


4. Secure steering arm assembly (17, Figure 4-4) ina position that is approximately 15 degrees downfrom its park position or 15 degrees up from itslowest position.

5. Loosen the hardware securing the dead-manswitch (2, Figure 4-7), to bracket (8, Figure 4-8).

6. Remove the cotter pin (1, Figure 4-6), then slidethe rod (2) into the brake lever (3) far enough topull the link pin (4) out of the lever (5).

7. Turn the link pin (4) to make the adjustment.

8. Slide the link pin (4) back into the lever (5), but donot insert the cotter pin (1) at this time.

9. Turn the drive wheel by hand to check brakeadjustment. If there is noticeable drag, go to step12. If there is no drag, go to step 10.

10. Disconnect the link pin (4).

11. Repeat steps 7 through 9 until adjustment is cor-rect providing noticeable drag.

12. Install the cotter pin (1).

13. Secure the steering arm in drive position and spinthe drive wheel to make sure there is no drag. Ifthere is any drag, carefully readjust only enoughto eliminate drag in the drive position.

14. Adjust dead-man switch (1, Figure 4-7) as follows:

a. Allow steering arm (17, Figure 4-4) to returnto the upright position.

b. Check that brake lever (15, Figure 4-8) hasactivated dead-man switch (2, Figure 4-7),indicated by an audible click.

c. If required, adjust position of dead-manswitch (2) by loosening nuts (4) and slidingswitch forward or back in mounting bracket(8, Figure 4-8) so that switch is activated,when brake starts to engage.

Figure 4-6. Brake Adjustment

d. Tighten nuts (4, Figure 4-7) so that dead-manswitch (2) is activated, but switch plunger isnot fully depressed.

e. Remove blocking and lower truck.

f. Install service cover (1, Figure 4-13), flatwashers (9), lockwashers (4), nuts (10), andscrews (3).

g. Connect battery connector.

4-4.2. Replacement of Brake Pads.


2. Block the wheels to prevent the truck from rolling.

Figure 4-7. Dead-Man Switch

R5142

R5143

4-10 PTW1104

Figure 4-8. Brake and Linkage


4. Position the steering arm (17, Figure 4-4) to theleft as far as possible, and secure the steeringarm down from its park position, so the mechani-cal brake is disengaged.

5. Remove the cotter pin (2, Figure 4-8) from the linkpin (17).

6. Slide the rod (16) with link pin (17) far enough intothe brake lever (15) to pull the link pin out of thelever (29).

7. Remove the two nuts (19) and lockwashers (31).

8. Carefully pull the bolts (20) just enough to clearthe mounting blocks (11) while you hold togetherthe remaining parts of the disc brake caliperassembly (18), then remove the assembly.

9. Remove the bolts (20), spacers (21), springs (22),and brake pad (23).

10. Remove the retaining ring (24), washer (25),spring (26), bracket (28), lever (29), and washer(30) from the brake pad (27).

R5144

PTW1104 4-11

11. Discard the springs (22 and 26) and brake pads(23 and 27). Replace them with new parts.

12. Assemble the washer (30), lever (29), bracket(28), spring (26), washer (25) and retaining ring(24) to the brake pad (27).

13. Assemble the brake pad (23), springs (22), andspacers (21) to the two bolts (20).

14. Slip the assembled parts onto the bracket (28)and hold them so the bolt holes are aligned.

15. Insert the bolts (20) through the mounting blocks(11), so the threaded portion of the bolts passescompletely through.

16. Assemble the two lockwashers (31) and nuts (19)to the bolts (20).

17. Slide the link pin (17) into the lever (29) andsecure the link pin with the cotter pin (2).

18. Remove the restrictions from the steering arm.

19. Refer to paragraph 4-4.1. above, and adjustbrake.

20. Install the motor compartment cover.


4-4.3. Replacement of Dead-Man Switch.


2. Block the wheels to prevent the truck from rolling.

3. Remove screws (3, Figure 4-13), nuts (11), lock-washers (4), flat washers (10), and motor com-partment (service) cover (1).

4. Remove screws (3, Figure 4-7), nuts (4), anddead-man switch (2).

5. Loosen the strain relief (1).

6. Separate switch housing. Tag and disconnectleads of cable from top of dead-man switch (2).

7. Connect leads of cable to top of replacementdead-man switch (2), as noted during removal.

8. Install replacement dead-man switch (2) onbracket assembly (8, Figure 4-8) and secure withscrews (3, Figure 4-7) and nuts (4).

9. Tighten strain relief (1).

10. Adjust the dead-man switch (Paragraph 4-4.1.above).

4-5. TRANSMISSION, DRIVE MOTOR, DRIVEWHEEL, AND PIVOT TUBE ASSEMBLY.

4-5.1. Transmission and Pivot Tube AssemblyRemoval.


2. Block load wheels.

3. Remove service cover.

4. Remove cap (3, Figure 4-9) from the pivot cap (4).

5. Label and disconnect wires.

6. Disconnect brake rods by removing cotter pin.

7. Remove steering assembly.

8. Support the transmission assembly and removethe two snap rings (1) and drive the pin (2) fromthe pivot cap (4).

9. Lower the pivot tube weldment (7) and transmis-sion down and out of the truck.

4-5.2. Transmission Initial Disassembly.


2. Securely block load wheels.

3. Remove service cover.

4. Remove magnetic drain plug (19, Figure 4-10)and drain transmission.

5. Turn steering arm to gain access to cover (43).

6. Remove fourteen screws (45) and lock washers(46) and cover (43).

7. Remove and discard gasket (42).

8. Remove thrust washer (29), gear (28) and key(51).

NOTE: When reassembling, be sure to replace thegasket and reinstall the magnetic drain plugbefore refilling the transmission with transmis-sion oil. Transmission holds 1-1/2 quarts oil.

4-5.3. Drive Axle Removal.

1. Perform Steps 1 through 8 in initial transmissiondisassembly.

2. Raise the rear of the truck using jacks or othersuitable means so that drive wheel is off floor.

3. Remove snap ring (41, Figure 4-10), gear (40),and key (39), then pull out shaft (33) and wheel(13). Washers (34 and 35) and seal (36) will fallfree.

NOTE: During reassembly be sure all washers, spac-ers, and the seal are reinstalled in propersequence as shown in the illustration.

4-12 PTW1104

Figure 4-9. Pivot Cap and Tube Installation

4-5.4. Drive Motor/Brake Assembly Removal.

1. Perform the initial disassembly, steps 1 through 8.

2. Remove the cotter pin that fastens the brake rodto the brake caliper lever.

3. Make sure the four cables to the drive motor areproperly labeled A1, A2, F1, and F2; then discon-nect the cables from the drive motor.

4. Remove the four bolts (2, Figure 4-10) and lockwashers (3) that hold motor mounting plate (4).

5. Tap motor mounting plate loose and removemounting plate with brake assembly bearings,bearing housing, seal, washer, and gear as a sin-gle piece.

6. If further disassembly is required remove pin (18)from gear (17) and proceed with disassembly.

NOTE: During reassembly be sure all parts are prop-erly sequenced on armature shaft and thatdowel pins in motor mounting plate arealigned with corresponding holes in transmis-sion housing.

4-5.5. Drive Motor Servicing.

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. If the truck does not run and the drive motor isat fault, inspect brushes (4, Figure 4-11 or 6, Figure 4-12) and commutator (on armature). Replace brushes ifthey are worn. Clean commutator of rough spots withfine sand paper and remove accumulations of looseparticles.

If the motor is to be disassembled, remove it from thetransmission as follows:


2. Make sure the four cables to the drive motor areproperly labeled A1, A2, F1, and F2; then discon-nect the cables from the drive motor.

3. Remove the four screws holding the motor mount-ing plate to the transmission.

NOTE: The motor mounting plate is positioned bydowel pins and must be tapped loose whenremoving the plate from the transmission.

4. Tap the motor mounting plate loose and removethe mounting plate with motor, brake caliper,brake disc and gear attached to armature shaft.

NOTE: Testing information available in Big Joe MotorMaintenance Manual.

5. When reinstalling motor on transmission, be suredowel pins are properly positioned so that arma-ture will line up with bushing in transmission; thentap motor mounting plate in place and fasten withfour screws.

R5310

PTW1104 4-13

Figure 4-10. Transmission Assembly

R5311

4-14 PTW1104

Figure 4-11. Drive Motor Assembly

Figure 4-12. Drive Motor Assembly

R5312

USED ON TRUCKS SERIAL NUMBERSPRIOR TO 371794

R6109

USED ON TRUCKS SERIAL NUMBERS371794 TO 376836

PTW1104 4-15

Figure 4-13. Power Section Frame and Motor Compartment Cover

R5313

4-16 PTW1104

4-6. BASE, FRAME, AND FORK SECTION.

4-6.1. General.

The base and frame section of the truck includes theinformation plates, decals, fork section, and loadwheels.

Removal and replacement of covers is straight-forwardand does not require detailed information, See Figure4-13. Make certain that all decals remain on the truckand are legible. If decals are damaged or missing theymust be replaced, See Figure 1-1.

4-6.2. Load Wheel Replacement.

1. Raise the forks.

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

3. Jack the forks up high enough to lift the loadwheels off the floor and block securely under thetips of the forks.

4. Drive the pin (5, Figure 4-14) from the shaft (11),and pull the shaft out of the wheel housing (9),

freeing the load wheel (6). Be careful not to losethe spacers (8).

NOTE: If load wheels are worn appreciably, it is rec-ommended that both front wheels bereplaced to assure equal load distribution onthe wheels.

5. Check bearings (7) for damage; rotate by hand,checking for smooth, non-binding rotation.

6. If either bearing (7) or the load wheel (6) is dam-aged, the entire load wheel assembly must bereplaced.

7. Install the load wheels as follows. One load wheelis installed in each wheel housing (9).

a. Start the shaft (11) into the wheel housing(9).

b. While sliding the shaft (11) completely intothe wheel housing (9), install one spacer (8),the load wheel (6) and another spacer (8), inthat order, onto the shaft (11).

c. Secure the shaft (11) by installing the pin (5).

Figure 4-14. Fork Section Assembly

R5314

PTW1104 4-17

8. Remove blocking and lower forks to the ground.

4-6.3. Frame Assembly: Fork Section and LiftLinkage Repair and Replacement.

1. Lift Linkage repair and replacement:

a. Lift complete truck to height sufficient to per-mit access to lift linkage under forks. Provideblocking under power section frame and attips of forks.

b. Drive pin (23, Figure 4-14) from shaft (28)and pivot (24). Support the pivot (24) andlinkage. Remove shaft (28) and washers(13). Remove springs (21) and lower thepivot (24) and linkage toward the floor.

c. Drive pin (3) from shaft (4) in fork. Supportthe wheel housing assembly and linkage.Remove shaft (4) and washers (13). Removewheel housing assembly and assembled link-age from the fork section (1).

d. Drive pin (5) from shaft (12) and wheel hous-ing (9). remove shaft (12) and washers (12),separating wheel housing (9) from rod (14).

e. If necessary for repair or replacement ofwheel housing (9) remove load wheels (Para-graph 4-6.2.).

f. Drive pin (23) from shaft (22) and pivot (24).Remove shaft (22) and washers (13), sepa-rating pivot from rod (16).

g. Drive pin (23) from shaft (22) and pivot (24).Remove shaft (22), washers (13) and rollerassembly (26) from pivot (24).

NOTE: Do not separate adjustable pull rods (14 and16), and turnbuckle (20) unless necessary forrod replacement.

h. If wheel housing (9), rod (14 or 16), or roller(26) must be replaced with a new part, omitstep i, below, for that component.

i. Inspect sleeve bushings (10, 15, 17 and 27)for excessive wear or other damage. Sleevebushings must be replaced if wall thicknessof bushing is less than 1/16 inch. Press innew bushings so they are flush with outsideedges within 0.02 inch. After installation,ream, if required, to bring bushing ID to 0.622+0.002/-0.000 inches.

j. Position roller assembly (26) with washers(13), as necessary, in pivot (24). Install shaft

(22) through pivot, washers and roller assem-bly, securing with pin (23).

k. If adjustable pull rods (14 and 16) were sepa-rated, assembly as follows:

(1) Install nut (18) and lockwasher (19) fullyonto front pull rod (14).

(2) Thread turnbuckle (20) approximately1-3/4" onto rod (14).

(3) Thread rear pull rod (16) approximately1-3/4" into turnbuckle (20).

l. Position rod (16) with washers (13), asrequired, in pivot (24). Ensure that the springbracket on rod raps around the underside ofrod, and install shaft (22). Secure shaft withpin (23).

m. Position rod (14) with washers (13), asrequired, in wheel housing (9). Install shaft(12) through wheel housing, washers andfront rod end, securing with pin (5).

n. Position wheel housing (9) and washers (13)as needed in fork section. Install shaft (4) andsecure shaft with pin (3).

o. Position pivot (24) to align pivot bore withbore in rear of fork and add washers (13) asneeded. Install shaft (28) and secure with pin(23). Attach springs (21) to each side of rod(16) and underside of fork.

p. Adjust the pull rods as follows:

(1) Clamp the wheel housing (9) in place asshown in Figure 4-15.

(2) Measure the 18.38" dimension as shownin Figure 4-15. If measurement is withintolerance, pull rod does not need adjust-ment.

(3) If adjustment is required, loosen the jamnut and adjust the turnbuckle as requiredto provide the 18.38" dimension.

(4) Lock adjustment by tightening the jamnut.

(5) Remove the clamp.

(6) Adjust other pull rod in same manner.

q. If removed, install load wheels (Paragraph 4-6.2. above).

r. Repeat steps b thru q, to repair/replace liftlinkage of other fork.

4-18 PTW1104

Figure 4-15. Pull Rod Adjustment Details

2. Fork Section and Power Section Frame Separa-tion:

a. Support entire truck on blocking, providingseparate blocks so that the fork section canbe fully supported when power section isremoved.

b. Disconnect battery.

c. Remove batteries (Paragraph 4-7.).

d. Remove cover (1, Figure 4-13).

e. Ensure that hydraulic pressure has beenrelieved from the lift circuit. Disconnecthydraulic line from fitting at cylinder andremove the fitting.

WARNING: Power section is heavy. Use care whilesecuring and lifting in order to preventinjury.

f. With suitable hoist, carefully lower the powersection (11, Figure 4-13) slightly, so cylinderrod end will clear socket in fork section. Withaccess through battery compartment ofpower section, raise or lower power section inorder to align access holes in backrest withbolts holding the upper cylinder mount.Remove bolts with extended socket, removemount.

g. The power section may now be hoistedstraight up sufficiently to allow the rollers onthe fork section to clear the channels on thepower section. Move the power section on

away from the fork section and place onblocking.

h. Remove the four rollers (29, Figure 4-14) andthrust bearings (30), noting thickness ofthrust bearings at each roller.

3. Fork Section Repair:

a. Inspect rollers (29, Figure 4-14) for wear, orother damage. Replace defective roller if nec-essary. Pack rollers with grease.

b. Inspect sleeve bushings (25) for wear orother damage. Bushing must be replaced ifwall thickness is less than 1/16 inch. Pressnew bushing into bore, flush with inside sur-face of fork channel.

c. Inspect fork section (1) for broken welds andweld as necessary. Replace fork section ifforks have been bent severely.

4. Power Section Frame Repair:

a. Repair of power section frame (11, Figure 4-13) is limited to chasing damaged threadsand welding of any broken welds.

b. Replace a worn or damaged U-clip nuts (2).

c. Removal of components mounted on powersection frame may be necessary to effectrepairs/welding of frame, refer to table of con-tents for identification of instructions on suchcomponents.

R5333

PTW1104 4-19

5. Fork Section and Power Section Frame Assem-bly:

NOTE: Prior to assembly of the fork section andpower section, check adjustment of the forkpull rods, paragraph 4-6.3.. Frame Assembly:Fork Section and Lift Linkage Repair andReplacement.C1.p.

a. Install thrust bearings (30, Figure 4-14), asnoted during removal, and rollers (29). If nec-essary, adjust the number/thickness of thrustbearings used to shim fork section rollers forproper fit into power section channels when anew fork section is installed.

b. Brush entire length of roller channels in frame(11, Figure 4-13) with grease (No. 2, Table 3-4).

c. With hoist lift power section so that the chan-nels are slightly above rollers on fork section.Move the power section into the fork sectionaligning rollers (29, Figure 4-14) with chan-nels of power section frame. Carefully lowerpower section, engaging rollers in channelsof power section frame.

d. Align access holes with bolt in top cylindermount.

e. With power section lowered sufficiently, posi-tion hydraulic cylinder in socket of frame andsupport cylinder with item 4, 5, 6 & 7 (4, Fig-ure 4-29).

f. Raise power section sufficiently to engagecylinder rod end in socket of fork frame.

g. Install hydraulic fittings in cylinders and con-nect hydraulic lines.

h. Install cover (1, Figure 4-13).

i. Lower truck to floor, and install batteries(Paragraph 4-7.).

j. Connect battery.

4-7. ELECTRICAL.

4-7.1. Battery Removal and Replacement (Figure4-16).

Batteries are pulled out and lifted from battery com-partment using the handles mounted on side of bat-tery case.

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

1. Disconnect the battery plug (2, Figure 4-16) fromthe connector.

2. Grab battery handle at exposed side of batteries,lifting slightly to clear retainer rod and pull batteryfrom side of power section frame.

3. Disconnect battery cables (2 and 6) from batter-ies.

4-7.2. Battery Cable Assemblies Replacement.

1. Disconnect batteries (paragraph 4-7.1.).

2. Remove screw (3, Figure 4-16) and lockwasher(4) to release battery cable assembly (2). Removeclamp (5) from cable assembly.

3. Remove screws and nuts that secure connector(handle) assembly (1) to connector on cableassembly (2).

4. Note routing of cables.

5. Pull cables (2) up out of battery compartment.

6. Replace entire battery cable assembly (2 and 6) ifcables are damaged. Use a multimeter to verifycontinuity.

7. Carefully route terminal end of cables (2) downinto battery compartment.

8. Position clamp (5) on cable assembly (2), allowingsufficient cable length to plug cable connector toreceptacles of battery charger and contactorpanel and secure with lock washer (4) and screw(3).

9. Connect battery cables (2 and 6) to batteries.

10. Connect battery plug (2) to TO DRIVE connector.

4-7.3. Resistor/Contactor Panel (Figure 4-17 &Figure 4-18).

1. Contactor Panel Removal.


b. Remove screws (3, Figure 4-13), nuts (10),lockwashers (4), flat washers (9), and motorcompartment (service) cover (1).

c. Refer to Figure 4-18 and tag and disconnectall electrical wires and cables, which connectto the contactor panel.

d. Remove two nuts (7, Figure 4-17) and lock-washers (6) to release and remove the con-tactor panel assembly and the speed controlresistor (11).

2. Contactor Panel Disassembly.

a. Carefully tag and disconnect all electricalwires and cable assemblies, as shown onFigure 4-18.

4-20 PTW1104

Figure 4-16. Storage Batteries and Connectors

Figure 4-17. Electrical Installation - Resistor Trucks

R5315

R5316

PTW1104 4-21

Figure 4-18. Contactor Panel Assembly - Resistor Trucks

R5317

4-22 PTW1104

Figure 4-19. Electrical System Installation - Transistor Trucks

b. Refer to Figure 4-18 for location and identityof component mounted on the panel andremove defective part.

c. The forward and reverse contactors used onthis panel are not repairable and must bereplaced if defective.

3. Contactor Panel Reassembly.

a. Install replacement parts in same locationand orientation as removed defective part.

b. Connect all electrical wires and cable assem-blies, as noted during removal and shown onFigure 4-18.

4. Contactor Panel Installation.

a. Position the contactor panel with resistor, andsecure with lockwashers (6, Figure 4-17) andnuts (7).

b. Refer to Figure 4-18 and connect all electricalwires and cables to the contactor panel, asnoted during removal.

c. Install motor compartment (service) cover (1,Figure 4-13) and secure with flat washers (9),lockwashers (4), nuts (10), and screws (3).

d. Connect the battery.

4-7.4. Transistor/Contactor Panel - TransistorTrucks (Figure 4-19 thru Figure 4-22).

NOTE: Erratic operation of a transistor controlledtruck, may be caused by defective controllercomponents. Before removing the contactorcontrol panel, perform troubleshooting proce-dures per paragraph 6-3. to determine correc-tive action to be taken.

1. Contactor Panel Removal.


b. Remove screws (3, Figure 4-13), nuts (10),lockwashers (4), flat washers (9), and motorcompartment (service) cover (1).

c. Refer to Figure 4-20 thru Figure 4-22 and tagand disconnect all electrical wires andcables, which connect to the contactor panel.

R5318

PTW1104 4-23

Figure 4-20. Contactor Panel Assembly - Transistor Trucks

R5319


4-24 PTW1104


R4133


PTW1104 4-25


R5319


4-26 PTW1104

d. Remove nuts (7, Figure 4-19) and lockwash-ers (6) to release and remove the contactorpanel assembly.

2. Contactor Panel Disassembly.

a. Refer to Figure 4-20 thru Figure 4-22 for loca-tion and identity of component mounted onthe panel and remove defective part.

b. The forward and reverse contactors used onthis panel are not repairable and must bereplaced if defective.

3. Contactor Panel Reassembly.

a. Install replacement parts in same locationand orientation as removed defective part.

b. Connect all electrical wires and cable assem-blies, as noted during removal and shown onFigure 4-20 thru Figure 4-22.

4. Contactor Panel Installation.

a. Install contactor panel and secure with lock-washers (6, Figure 4-19) and nuts (7).

b. Refer to Figure 4-20 thru Figure 4-22 andconnect all electrical wires and cables to thecontactor panel, as noted during removal.

c. Install motor compartment (service) cover (1,Figure 4-13) and secure with flat washers (9),lockwashers (4), nuts (10), and screws (3).

d. Connect the battery.

4-7.5. Horn Replacement.

To replace the horn, proceed as follows:

NOTE: The spike suppressor (4, Figure 4-23) is onlyapplicable to transistor units.

1. Perform steps 2a and 2b, above.

2. Tag and disconnect all electrical connections fromhorn (5).

3. Remove nuts (1), lockwashers (2), and flat wash-ers (3) to release and remove the horn (5).

4. If working with a transistor unit, check the spikesuppressor assembly (4) for damage. If any partis damaged, the entire spike suppressor assem-bly (4) must be replaced.

5. Install horn (5) and secure with nuts (1), flat wash-ers (3), and lockwashers (2).

6. Connect all electrical wires to the horn, as notedduring removal.

7. Install motor compartment (service) cover (1, Fig-ure 4-13) and secure with flat washers (9), lock-washers (4), screws (3), and nuts (10).


4-7.6. Battery Charger (Figure 4-24).

The battery charger is mounted in the upper right sideof the power section frame under the top cover. Theplug-in connector is accessible through an opening inthe top cover, which also carries the charger ammeter.All replaceable parts are shown in Figure 4-24.

4-7.7. Wire Harness Testing.

1. Wire harnesses are illustrated and identified onthe figures in this manual containing the compo-nents they are associated with. As an aid to test-ing, individual wires in each harness have theirwire numbers permanently marked on both ends.Refer to the wiring diagram (Figure 4-25 for Resis-tor Units. Figure 4-26 thru Figure 4-28 for Transis-tor Units).

2. Testing procedures are as follows:


b. Tag and disconnect electrical wires as neces-sary.

c. Disconnect plug(s) and/or receptacle(s), ifany.

d. Using a multimeter, check all individual wireleads for continuity. Continuity must exist ineach individual wire lead.

3. If a wire harness fails continuity test, it must bereplaced. Make careful note of harness routing,and location of any clamps or wire ties beforeremoving. Route new harness, and install anyclamps or wire ties, as noted during removal.

4. Connect electrical wires, as noted during removal.

5. Connect any plug(s) and/or receptacle(s), asnoted during removal.


4-7.8. Wiring.

Electrical wiring installation for resistor trucks is shownon Figure 4-17 and Figure 4-18. Electrical wiringinstallation for transistor trucks is shown on Figure 4-19 thru Figure 4-22. When removing or installing elec-trical wires or cables, refer to the wiring diagrams (Fig-ure 4-25 for resistor trucks, Figure 4-26 thru Figure 4-28 for transistor trucks), to help ensure proper installa-tion.

PTW1104 4-27

Figure 4-23. Horn Installation

The following procedure gives instruction for separat-ing wires and cable for replacement. The entire proce-dure must be carefully followed for removal of thetransmission.

1. Removal.

a. Refer to paragraph 4-3. for replacement ofcontrol cable. Refer to paragraph 4-7.7.above, for testing and replacement of wireharness assemblies.

b. Disconnect battery.

c. Remove screws (3, Figure 4-13), nuts (10),lockwashers (4), flat washers (9), and motorcompartment (service) cover (1).

d. Refer to Figure 4-17 for resistor trucks or Fig-ure 4-19 thru Figure 4-22 for transistor trucksand label all wire and cable leads connectedto motor and deadman switch, then discon-nect the leads.

e. Refer to Figure 4-17 or Figure 4-19 andremove clamps (5) from transmission andunderside of frame top-plate. Note position ofthe different size hardware to help ensureproper installation.

f. Remove wire ties as necessary to separatecables. Disconnect control cable assembly(3) at large connector, located at contactorpanel.

g. If removing the transmission, pull end of con-trol cable up through opening on side oftransmission housing.

Figure 4-24. Battery Charger Installation

R5320

R5321

4-28 PTW1104

NOTES

PTW1104 4-29

Figure 4-25. Wiring Diagram - Resistor Trucks

R5322

4-30 PTW1104

Figure 4-26. Wiring Diagram - Transistor Trucks

R5323

USED ON TRUCKS SERIAL NUMBERS PRIOR TO 338608

PTW1104 4-31

Figure 4-27. Wiring Diagram - Transistor Trucks (Sheet 1 of 2)

R4131-1

USED ON TRUCKS SERIAL NUMBERS 338608 TO 373233

4-32 PTW1104


R4131-2


PTW1104 4-33


R6126


4-34 PTW1104


R6127


PTW1104 4-35

Figure 4-29. Hydraulic System Installation

h. Inspect all electrical wires and cables fordamage. Using a multimeter, check suspectwires for continuity.

i. Tag and disconnect a damaged wire or cableand install replacement part in same location.

2. Installation.

a. If removed, feed end of electric control cablethrough opening in side of transmission onwhich bracket is mounted.

b. Connect all electrical wires and cables asnoted during removal and shown on Figure 4-17 or Figure 4-19.

c. Secure cables to transmission housing andpower section frame with clamps and associ-ated hardware. Use wire ties to bundle cablesand wires as noted during removal.

d. Pivot transmission through entire turningrange, observing that electrical cables andwire leads will flex properly and not becomecaught or pinched at any time.

e. Check operation of dead-man switch andbrake. Adjust as necessary (Paragraph 4-4.).

f. Install cover (1, Figure 4-13) and secure withflat washers (9), lockwashers (4), nuts (10),and screws (3).

g. Operate truck to ensure electrical connec-tions were properly made.

h. Connect the battery.

4-8. HYDRAULICS.

4-8.1. Line and Fitting Replacement.

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

R5324

4-36 PTW1104

Figure 4-30. Pump, Motor and Reservoir Assembly

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

1. Lower forks fully.

2. Remove battery (Paragraph 4-7.).


CAUTION: Hydraulic oil can damage parts. Wipe offany oil immediately. Provide a containerunder line or fitting, before disconnect-ing.

4. Refer to Figure 4-29 and remove leaking line orfitting and replace it with a new line or fitting.

5. Remove the vent plug (15, Figure 4-30), andelbow (13). Check level of hydraulic oil. Hydraulicoil must be one inch below bottom of elbow (13). If

required, add hydraulic oil to bring to proper level.Use hydraulic oil listed in Table 3-4.

6. Reinstall the vent plug (15) and connect the bat-tery.

7. Operate the lift lower buttons to refill cylinder andlines with hydraulic oil.

8. Lower forks fully and disconnect battery.

9. Remove the vent plug (15) and elbow (13) andrecheck level of hydraulic oil. Hydraulic oil must beone inch below bottom of elbow (13). If required,add hydraulic oil to bring to proper level. Usehydraulic oil listed in Table 3-4.

10. Reinstall vent plug.


12. Install the battery (Paragraph 4-7.).

R4356

PTW1104 4-37

Figure 4-31. Hydraulic System Installation

4-8.2. Hydraulic Pump, Motor, and ReservoirAssembly (Figure 4-30).

The hydraulic pump, motor, and reservoir assemblymay be repaired. The motor and control valves can berepaired, however, a defective pump must be replacedas a complete unit. Proceed as follows to remove anddisassemble the hydraulic pump, motor, and reservoirassembly.

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

1. Lower forks fully and disconnect battery.

2. Remove screws (3, Figure 4-13), nuts (10), lock-washers (4), and flat washers (9) to release andremove motor compartment (service) cover (1).

3. Tag and disconnect all electrical wires from thepump, motor, and reservoir assembly (14, Figure4-29).

4. Remove hose assembly (8) and adapter (9).

5. Remove screws (1), lockwashers (2), and flatwashers (3), to release and remove pump, motor,and reservoir assembly (14).

6. Remove vent plug (15, Figure 4-30) and drainhydraulic oil from reservoir into a clean bucket orsuitable container.

7. Refer to Figure 4-29 for parts relationship andreplace damaged components.

4-8.3. Lift Cylinder Removal.

Remove lift cylinder as instructed in paragraph 4-6.3.,step 2.

R5325

PACKING KIT901498 CONTAINS:

ITEM QTY1 12 14 1

4-38 PTW1104

4-8.4. Lift Cylinder Repair.

To rebuild or replace components in a lift cylinder, pro-ceed as follows:

1. Secure the lift cylinder in a vise, clamping lightlyat the base of the cylinder.

2. With spanner wrench, remove the cylinder head(3, Figure 4-31) from the cylinder weldment (6).

3. Withdraw the cylinder rod (5) from the cylinder.

NOTE: If the, cylinder weldment (6), cylinder rod (5),or cylinder head (3) is damaged, the entire liftcylinder must be replaced.

4. Replace all wipers, seals and damaged or wornparts.

5. Coating all parts with hydraulic oil (Table 3-4).

6. Insert cylinder rod (5), with attached parts, intocylinder weldment (6).

7. Install cylinder head and tighten to 5-7 lbs/ft.

4-8.5. Hydraulic Pressure Adjustment.

The relief valve is factory set to open at the rated pres-sure setting for the pump (not to exceed 2575 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.


3. Disconnect hose (8, Figure 4-29) from elbow atpump and connect a pressure gauge of adequaterange (0-3000 psi) to the elbow.

4. Activate pump motor and observe reading onpressure gauge. If pressure reading is between2475 and 2575 psi, the relief valve is functioningproperly and does not need adjustment. If pres-sure reading is below 2475 psi or above 2575 psi,proceed as follows to adjust relief valve:

CAUTION: Do not set pressure too high or hydraulicsystem may be damaged. Factory rec-ommended limits of 2475 to 2575 psishould be observed. Under no circum-stances should pressure be set above2575 psi.

5. With pump motor running, observe pressuregauge and set pressure between 2475 and 2575psi by turning adjusting screw (14, Figure 4-30)clockwise to increase pressure or counterclock-wise to decrease pressure.

6. Deactivate pump motor, disconnect pressuregauge, and reconnect hose.


4-9. DECALS AND TRIM.

4-9.1. Painting Requirements.

Clean all dirt, scale, and other foreign matter from sur-faces to be painted. Touch up paint on frames and pullrods with yellow enamel (901201). Touch up paint onremaining parts with black satin enamel (901202).

4-9.2. Decals and Plates.

Refer to Figure 1-1 for location and identification ofdecals and information plates. Make sure decals andplates are legible and securely attached.

PTW1104 4-39

NOTES

4-40 PTW1104

SECTION 5OPTIONS

5-1. BATTERY DISCHARGE INDICATOR.

Replacement parts for the optional battery dischargeindicator are detailed in Figure 7-24. Refer to the wir-ing diagram (Figure 4-25 for resistor trucks. Figure 4-26 thru Figure 4-28 for transistor trucks.) to helpensure proper connections.

5-1.1. Battery Discharge Indicator Replacement.

1. Operation of the battery discharge indicator (1,Figure 7-24) may be checked by comparing itsreading against a hydrometer. Indicator shouldshow a full charge when hydrometer shows a spe-cific gravity of 1.260 to 1.275.

2. To replace the battery discharge indicator (1), pro-ceed as follows:


b. Remove screws (6, Figure 4-13), lockwash-ers (4), flat washers (7), and right hand cover(8).

c. Tag and disconnect terminals (2, Figure 7-24).

d. Remove two knurled nuts and U-bracket, partof battery discharge indicator (1), to releaseand remove the indicator.

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

e. Install battery discharge indicator (1) andsecure with supplied U-bracket and nuts. Ifrequired, trim the U-bracket legs to properlength.

f. Connect terminals (2), as noted duringremoval.

g. Install right hand cover (8, Figure 4-13) andsecure with flat washers (7), lockwashers (4),and screws (6).


5-2. HOURMETER.

The hourmeter is available for attachment to the motorcircuits to indicate use of the drive and lift functions.Refer to Figure 7-27 for replacement parts. Refer tothe wiring diagram (Figure 4-25 for resistor trucks. Fig-ure 4-26 thru Figure 4-28 for transistor trucks.) to helpensure proper connections.

5-2.1. Hourmeter Replacement.

1. Operation of the hourmeter (3, Figure 7-27) maybe checked against a watch.

2. To replace the hourmeter (3), proceed as follows:


b. Remove screws (6, Figure 4-13), lockwash-ers (4), flat washers (7), and right hand cover(8).

c. Tag and disconnect terminals from hourmeter(3, Figure 7-27).

d. Remove nuts (10), lockwashers (9), andscrews (2) to release and remove hourmeter(3), diode assembly (8), and insulating pad(7).

e. Install hourmeter (3), insulating pad (7), anddiode assembly (8), and secure with screws(2), lockwashers (9), and nuts (10).

f. Connect terminals to hourmeter (3).

g. Install right hand cover (8, Figure 4-13) andsecure with flat washers (7), lockwashers (4),and screws (6).


5-3. KEYSWITCH.

The optional keyswitch is shown in Figure 7-25. Thekeyswitch installation is accomplished by inserting thesupplied wiring into wire number 3, of control panelharness, at the slip-on connector of the in-line fuse.Refer to the wiring diagram (Figure 4-25 for resistortrucks. Figure 4-26 thru Figure 4-28 for transistortrucks) to help ensure proper connections.

5-4. COLD CONDITIONING PACKAGE.

Continuous operation of the PTW lift trucks at temper-atures below 32° F (freezing) in applications such asmeat lockers and freezers, requires the changing ofoils and grease, and modification of the control headand deadman switch as shown in Figure 7-26. Forintermittent operation under 32° F, the oils and greaseneed not be changed. Refer to the wiring diagram (Fig-ure 4-25 for resistor trucks. Figure 4-26 thru Figure 4-28 for transistor trucks) to help ensure proper connec-tions.

PTW1104 5-1

5-5. 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 7-28.

5-6. CASTER

Casters are available for additional stability. Identifica-tion of replacement parts are shown in Figure 7-29.

5-2 PTW1104

SECTION 6TROUBLESHOOTING

6-1. TROUBLESHOOTING CHART.

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

Truck will not run, lift system does not operate.

a. 300 AMP fuse blown Check fuse (Figure 4-18 for Resistor Units. Figure 4-20 thru Figure 4-22 for Transistor Units.) Replace if necessary

b. Battery dead or disconnected. Check battery and quick disconnect (Fig-ure 4-16)

c. Defective wiring. Check for open circuit and repair as required.

d. Keyswitch, if equipped, defec-tive.

Bypass keyswitch to determine if bad.

Truck does not run forward or reverse. All other functions operate normally.

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

Tighten all loose connections before fur-ther troubleshooting

b. Defective deadman brake switch.

Check and replace switch if defective.

c. Switch in control head broken. Check and replace switch if defective.

Truck runs forward but not in reverse.

Defective switch in control head, or defective contactor.

Check for positive dc voltage at number 2-wire on reverse contactor. If not present when steering arm is in operating position and control lever is in reverse, reverse switch is defective. If voltage is present, contactor is defective.

Truck runs in reverse but not in forward.

Defective switch in control head, or defective contactor.

Check for positive dc voltage at number 1-wire on forward contactor. If not present when steering arm is in operating position and control lever switch is in forward, for-ward switch is defective. If voltage is present, contactor is defective.

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

Defective speed control switch in control head, or defective by-pass contactor.

Check for positive dc voltage at number 5-wire on by-pass contactor. If not present when steering arm is in operating position and control lever is in full speed reverse, speed control switch is defective. If voltage is present, contactor is defective.

Truck runs forward and reverse at second or third speed only. Truck does not move when control is in first speed position. All else is nor-mal.

a. Resistor Trucks: Defective or open speed control resistor.

Check for clean, tight connection. Check for continuity and replace as required.

b. Transistor Trucks: Defective transistor control.

Replace transistor control.

PTW1104 6-1

Mechanical brake grabs when steering arm is in operating position.

Brake linkage overadjusted. Adjust brake.

Oil sprays or flows from top of a lift cylinder.

Defective packing in lift cylinder. Overhaul lift cylinder and install new pack-ing, seal, and wiper ring.

Squealing sounds when lifting forks.

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

b. Dry channels in mast. Apply grease.

c. Defective carriage bearing. Replace bearing.

Lift carriage does 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 valve.

b. Worn lift cylinder packing. Repack cylinder.

c. Load larger than capacity. Refer to I.D. plate for capacity.

d. Defective lift motor solenoid. Replace.

e. Battery charge low. Charge battery.

Forks do not lift, 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 on the motor. Repair or 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 cylinders, 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 and lower-ing valve; look for blockage in hydraulic line. Repair/adjust as required.

Load will not hold. a. Oil bypassing internally between check valve and adapter body.

Disassemble, clean, and reassemble. Replace worn parts as required.

b. Worn lift cylinder packing. Replace cylinder packing.

Forks creep downward under load when in a raised position.

Leak in hydraulic system cylinder packing or lowering valve.

Check lowering solenoid valve and internal check valve for blockage preventing valve from closing completely to block oil. Look for leaking fitting in hydraulic line. Check pump for leakage back into reservoir. Repair or replace as required.

Steering arm does not return to the upright position.

a. Return spring improperly adjusted.

Readjust spring tension.

b. Binding brake linkage or elec-trical cable.

Check and free the binding item.


6-2 PTW1104

6-2. CONTACTOR AND SWITCH TROUBLESHOOT-ING.

If the truck does not run in one of the modes (Exam-ple: truck runs in forward speed, but not in reverse),the following tests can be performed to determinewhether the problem is in the switches or the contactorunit itself.

6-2.1. Contactor Testing.

1. Make certain battery is in good condition and fullycharged before beginning tests.

2. Disconnect the battery and place strips of card-board between the contactor tips to prevent cur-rent from flowing during the test.

3. Reconnect the battery.

4. Place the VOM test meter on the 50V scale andconnect the test probes to the (+) and (-) coil con-nections of the suspect contactor (Figure 6-1).

NOTE: Testing of the reverse contactor is shown inFigure 6-1.

5. If the truck is equipped with a keyswitch, turn it onand place the steering control in the run position(brake off) and depress the speed control.

6. Voltage should read 24 volts, as applicable. If volt-age does not read 24 volts, the problem is in theswitches or wiring leading to the contactor unit.(See Paragraph 6-2.2. for switch testing.) If 24

volts is present, the problem is in the contactorunit, and the contactor must be disassembled anddefective parts replaced.

6-2.2. Switch Testing.


2. Set the VOM test meter on the RX1 scale.

3. Resistor Trucks: Connect the meter test probesto the common #3 (#11 for pushbutton switches)and the suspect switch lead* at the terminal con-nector.

Transistor Trucks: Connect the meter testprobes to the common #3 (#10 for push buttonswitches) and the suspect switch lead * at the ter-minal connector.

*NOTE: #2 switch lead for the reverse switch (transis-tor trucks) is shown in Figure 6-2.

4. If the truck is equipped with a keyswitch, turn it onand lower the control handle to the driving posi-tion and depress the suspect switch.

5. Resistance should read zero ohms, (or a smallamount of ohms).

6. If resistance is present (10 ohms or more), theswitch or wiring leading to the connector is defec-tive and must be repaired or replaced.

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 exces-sively starting or stopping the truck.

a. Worn steering arm pivot bush-ings.

Replace bushings if difference between ID of pivot bushings (5, Figure 4-9) and OD of pivot tube (7) exceeds 1/32 inch.

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

Drive motor is jerky. Motor commutator damaged. Replace motor.


PTW1104 6-3

Figure 6-1. Contactor Testing

R5326

6-4 PTW1104

Figure 6-2. Switch Testing

R5327

PTW1104 6-5

6-3. TRANSISTOR CONTROLLER TROUBLE-SHOOTING.

Refer to wiring diagrams included in SECTION 4 forcomplete wiring diagram for this truck. Refer to thesediagrams and the schematic for tracing of electrical cir-cuits during troubleshooting and testing procedures.

6-3.1. Circuit Operation.

While operation of the transistorized control system istransparent to the operator, it is helpful to understandthe operating principles and features of the transistorcontroller when troubleshooting trucks equipped withthis controller. The controller is mounted on the con-tactor electrical panel, installed within the main hous-ing of the lift truck. Figure 6-3 identifies the contacts ofa typical controller.

1. Smooth stepless operation.

The Big Joe custom transistor controller allowssuperior operator control of the vehicle's drivemotor speed. The amount of current delivered tothe motor is set by varying the "on" time (dutycycle) of the controller's MOSFET transistors.This technique, called "pulse width modulation"(PWM), permits silent, stepless operation.

2. Current multiplication

During acceleration and during reduced speedoperation, the controller allows more current toflow into the motor than flows out of the battery.The controller acts like a dc transformer, taking inlow current and high voltage (the full battery volt-age) and putting out high current and low voltage.The battery only has to supply a fraction of thecurrent that would be required by a conventionalcontroller (in which the battery current and motorcurrent are always equal). The current multiplica-tion feature gives vehicles using these controllersdramatically greater driving range per batterycharge.

3. Acceleration limiting

A built-in acceleration limiting circuit maintains amaximum rate of power increase to the motor. Iffull throttle is applied at start-up, the accelerationramp setting determines how quickly the output ofthe controller increases. The standard setting issuch that with full throttle applied, the controllerrequires approximately one second to reach fulloutput. This feature contributes to smooth, gentle

starts. (See adjustment instructions to adjustacceleration ramp setting.)

4. Current limiting

The transistor controllers limit the motor current toa preset maximum. This feature protects the con-troller from damage that might result if the currentwere limited only by the motor demand. The cur-rent limit feature also protects the rest of the sys-tem. By eliminating high current surges duringvehicle acceleration, the stresses on the motorand batteries are reduced and their efficiency andservice life are improved. Similarly, there is lesswear and tear on the vehicle drivetrain, as well ason the ground on which the vehicle rides (animportant consideration with golf courses and ten-nis courts, for example).

The maximum motor current can be factory-set toa lower value than the standard maximum ifrequested. For further flexibility, the current limitsetting on some models is field-adjustable. (Seeadjustment instructions.)

5. Plugging

A form of electrical braking called plugging can beused to slow the vehicle. When the motor isreversed with the accelerator advanced (i.e.,when the vehicle is moving), the armature acts asa generator. current from the armature flowsthrough a plug diode in the controller. The control-ler regulates the current in the motor field windingto give an appropriate level of plugging torque.The vehicle slows smoothly to a stop, then auto-matically accelerates in the other direction. A1 kHz tone may be heard during plugging. Themaximum plugging current is factory set per cus-tomer requirements, and is also field adjustable(see adjustment instructions).

6. Undervoltage protection

The control circuitry requires a minimum batteryvoltage to function properly. The controller istherefore designed so its output is graduallyreduced if the battery voltage falls below a certainlevel; the cutoff voltage for the various models islisted in the specifications (See Table 6-1 andTable 6-2). Reducing the output to the motorallows the battery voltage to recover, and an equi-librium is established in which the battery suppliesas much current as it can without falling below thecutoff voltage.

6-6 PTW1104

Table 6-1. Controller SpecificationsPrior To Serial Number 373234

Big Joe Model 005467-01 005467-02

Input Voltage 12 24-36

Current Limit 400 Amps* 400 Amps*

Rating:2 Minute 300 Amps 300 Amps5 Minute 210 Amps 210 Amps1 Hour 135 Amps 135 Amps

Voltage Drop @ 100 Amps 0.25 V 0.25 V

Under-voltage Cutback 9 V 16 V

Max F/R+1A Current 2 Amps 2 Amps

Operating Frequency 15 kHz 15 kHz

Standby Current mA mA

Standard Throttle Input 0-5000 ohms, 0-5000 ohms,+10% +10%

* 30 Second rating.

Table 6-2. Controller SpecificationsSerial Number 373234 to 376836

Big Joe Model 907200-02

Input Voltage 24

Current Limit 250 Amps*

Rating:1 Minute 250 Amps2 Minute 200 Amps5 Minute 150 Amps1 Hour 100 Amps

Voltage Drop @ 100 Amps 0.25 V

Under-voltage Cutback 16 V

Max F/R+1A Current 2 Amps

Operating Frequency 15 kHz

* 30 Second rating.

Figure 6-3. Full Feature Electronic Motor Controller

PTW1104 6-7

7. Overvoltage protection

Similarly, the controller has a means of preventingoperation when battery voltages are too high forproper functioning. Excess voltage can occur froman unregulated battery charger or from improperor faulty wiring.

8. Thermal protection

Because they are well designed thermally, thecontrollers barely get warm in normal operation.Overheating can occur, however, if the controlleris undersized for its application or otherwise over-loaded. If the internal temperature of the controllerexceeds 165°F, the current limit drops off steadilyuntil it is reduced to zero at 200°F. This allows thevehicle to be operated at a reduced performancelevel in order to permit maneuvering out of theway and stopping in a good place. After the con-troller cools down, full current limit and perfor-mance return automatically. Although this actionis not damaging to the controller, it does suggesta mismatch. If thermal cutback occurs often innormal vehicle operation, the controller is proba-bly undersized for the application, and a highercurrent model should be used. The controllershifts frequency during overtemperature from itsnormal 15 kHz to 1 kHz, providing an audible tonealerting the operator to the overtemperature con-dition.

The controller is also protected from undertem-perature. Should its internal temperature fallbelow -25°C (from being parked overnight in anicehouse, for example), the current limit will be 1/3the maximum. Once the controller warms above -25°C, full current limit and performance returnautomatically.

9. Accelerator fault protection (runaway protection)

To prevent uncontrolled operation the controllershuts off the motor output in the event of a shortcircuit fault in the accelerator or its wiring. Thethrottle configuration is a 2-wire potentiometerranging from 5000 ohms for full off to 0 ohms forfull on. The controller returns to normal operationwhen the fault (e.g., accelerator wiring, brokenconnectors, potentiometers that fail or are set tostart at 0) has been corrected.

10. Controller fault protection (Prior to SerialNumber 373234)

Faults can be caused internally (e.g., shortedtransistors) or externally (e.g., wrench or hard-ware dropped across controller terminals). Whiledisabled, the controller's direction contactor out-put and internal logic are both off.

Faults are detected by monitoring the controller'sM-output. If M-remains low for more than 20 ms, afault is detected. Fault protection is disabled forthrottle demand greater than 80%

To recover from a fault, the F/R switch must beturned off and back on again. If the fault has beencorrected, the controller will turn back on.

11. Fault Detection (Serial Number 373234 To376836)

An internal microcontroller automatically main-tains surveillance over the functioning of the con-troller. When a fault is detected, the appropriatefault code is signaled via the LED, externally visi-ble on the side of controller (See Figure 7-23 forLED location on controller). The diagnostic codesflashed by the LED are listed in Table 6-4.

If the fault is critical, the controller is disabled.More typically, the fault is a remediable condition -for example, an undervoltage fault is clearedwhen the condition is removed.

The automatic fault detection system includes:

contactor coil open / shorted driver (F/R andshunt contractor)

contactor driver overcurrent / contactor coilshort

contactor welded

emergency reverse circuit check

M- output fault

memory checks upon start-up

overvoltage cutback

power supply out of range (internal)

throttle fault

undervoltage cutback

watchdog (external and internal)

6-8 PTW1104

a. Hand Held Programmer.

A hand held programmer is available that isdesigned specifically for use with the control-ler. It serves dual functions of reading diag-nostic data provided by the controller andadjusting certain performance values of thecontroller. The programmer (Part Number005472-02) is available through your Big Joedealer. If you require dealer location informa-tion contact Big Joe Manufacturing Co.phone number 847-298-9800.

b. Fault Recording.

Fault events are recorded in the controller'smemory. Multiple occurrences of the samefault are recorded as one occurrence.

The fault event list can be loaded into the pro-grammer for readout. The Special Diagnos-tics mode provides access to the controller'sdiagnostic history file - the entire fault eventlist created since the diagnostic history filewas last cleared. The Diagnostics mode, onthe other hand, provides information aboutonly the currently active faults.

c. Fault Recovery (including recovery fromdisable).

Almost all faults require a cycling of the KSIor brake input to reset the controller andenable operation. The only exceptions areshown in Table 6-3.

12. Weather resistance

All controllers are housed in rugged epoxy-sealed, anodized aluminum extrusions that pro-vide excellent environmental protection.

13. Emergency reverse: enhanced plugging current

Emergency reverse (or "belly button") switchescan be mounted on the handles of walkie vehi-cles. The emergency reverse switch is wired tothe controller and other vehicle electronics in sucha way that if the button is pressed against theoperator by the advancing vehicle, the controllerenables enhanced plugging current to stop thevehicle quickly and revere its direction.

Table 6-3. Fault Recovery Exceptions.

14. Arcless F/R and bypass contactor switching

Each time the F/R switch passes through neutral,the controller's output is rapidly turned off (even ifthe throttle is held on) so that all motor currenthas stopped by the time the direction contactordrops out. Controller output always starts at zeroand increases smoothly at the set accelerationrate each time a new direction is selected. Bypasscontactor operation is also arcless, when inter-rupting currents less than the controller's currentlimit.

15. High pedal disable (HPD)

When the controller (KSI) is turned on, it willsense a “high” (advanced accelerator and willinhibit the output until the accelerator is releasedand reapplied. By preventing the unit KSI frombeing turned on with the throttle depressed, thissafety feature (also called Neutral Start) requiredthe truck to start smoothly from zero throttle whenthe battery is plugged in. It also protects againstsudden starts caused when problems in the throt-tle linkage (e.g., bent parts, broken return sprint)give a partial or full throttle signal to the controllereven with the accelerator released when the bat-tery is plugged in.

6-3.2. General Checkout (Serial Number 373234 To376836).

Carefully complete the following checkout procedure. Ifyou find a problem during the checkout, refer to Para-graph 6-3.4. for further information.

The checkout can be conducted with or without thehandheld programmer (See Paragraph a.). The check-out procedure is easier with a programmer. Otherwise,observe LED for codes.

FAULT RECOVERY

anti-tiedown release and re-select Mode 1

contactor overcurrent when condition clears

emergency reverse BB re-applied or brake cycled

HPD lower throttle to below HPD threshold

overvoltage when battery voltage drops below over-voltage

SRO when proper sequence is followed

thermal cutback when temperature comes within range

throttle fault clears when condition gone

undervoltage when battery voltage rises above under-voltage

PTW1104 6-9

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 thatthe brake is applied (brake switch open),the throttle is in neutral, and the forward/reverse switches are open.

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.

2. Turn the keyswitch on. The programmer should"power up" with an initial display, and the control-ler's Status LED should begin steadily blinking asingle flash. If neither happens, check for continu-ity in the keyswitch circuit and controller ground.

3. If you are using a programmer, put it into the diag-nostic mode by pressing the "DIAGNOSTICS"key. The display should indicate "No KnownFaults."

Release the brake by pulling down the control arminto the operating position. The LED should con-tinue blinking a single flash and the programmershould continue to indicate no faults. If there is aproblem, the LED will flash a diagnostic code andthe programmer will display a diagnostic mes-sage. If you are conducting the checkout without aprogrammer, look up the LED diagnostic code inTable 6-4.

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, for-ward/reverse contactors, and motor. The motorshould run proportionally faster with increasingthrottle. If not, refer to Paragraph 6-3.4.

5. If you are using a programmer, put it into the testmode by pressing the "TEST" key. Scroll down toobserve the status of the forward, reverse, brake,emergency reverse, and mode switches. Cycleeach switch in turn, observing the programmer.

Each input should show the correct state on theprogrammer.

6. Check the controller's fault detection circuitry asdescribed in paragraph 6-3.10.

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. Verify that theplug braking option is as desired (variable orfixed).

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

6-3.3. Troubleshooting (Prior To Serial Number373234).

The following procedures are to fix vehicles that don'toperate properly. Refer to wiring diagrams included inSECTION 4 when conducting these tests. Make surethe controller is hooked up as shown in Figure 6-3.Refer to the wiring diagram and schematic for yourvehicle. These tests require a general purpose voltohmmeter; you can use either a conventional "V-O-M"or an inexpensive digital voltmeter.

In general, when a problem has been isolated to thecontroller, remove and replace it. If the source of theproblem has not been determined or is suspected tobe within the truck (not the controller), proceed asdirected.

NOTE: Working on electric vehicles poses somedangers. You must protect yourself againstrunaways, high current arcs, and outgassingfrom lead acid batteries:

Runaways - Some fault conditions couldcause the vehicle to run out of control. Wesuggest that you jack up the vehicle and getthe drive wheels off the ground beforeattempting these procedures or any otherwork on the motor control circuitry.

High current arcs - electric vehicle batteriescan supply very high power for short times. if

6-10 PTW1104

they are accidentally short circuited, arcs canoccur. Always open the battery circuit beforedoing work on the motor control circuit. Wearsafety glasses and use properly insulatedwrenches to prevent accidental shorts.

Lead acid batteries - Charging or discharg-ing batteries generates hydrogen gas, whichcan build up in and around the batteries.Always follow the battery manufacturer's rec-ommendations when working around batter-ies. Wear safety glasses.

1. Check for Power to the Controller

a. Leave the keyswitch off for these tests (iftruck is so equipped).

b. Verify that battery (-) connects to the B- ter-minal of the controller. connect voltmeter (-)lead to this point.

c. Connect voltmeter (+) to the battery side ofthe power fuse. Check for full battery voltage.If it is not there, the trouble is in the batterypack or the cables to it.

d. Connect the voltmeter (+) lead to the control-ler B+ terminal. You should read full batteryvoltage. If this voltage is zero or close to zero,the trouble is either a bad controller, a badpower fuse, or an incorrectly connectedcable. Trace the cable to make sure it ishooked up right. If these check out, the con-troller is malfunctioning.

2. Check for Contactor Operation and KeyswitchInput (KSI)

a. Turn the key on and move the accelerator inforward or reverse, until the microswitch oper-ates.

b. This should cause the main contactor tooperate with an audible click. Connect thevoltmeter across the contactor coil terminal.You should see full battery voltage.

c. The controller KSI terminal (top push on)should also be getting full battery voltage.Verify this with the voltmeter. Connect thevoltmeter (-) to the controller B- terminal, andthe voltmeter (+) to the controller's KSI termi-nal.

d. If the contactor and KSI terminal are not get-ting voltage, that's the problem. Use the volt-meter to find out where it is not gettingthrough. Connect the voltmeter (-) to the con-

troller's B- terminal and check the followingpoints with the voltmeter (+) lead to trace theflow:

(1) First, check both sides of the control wir-ing fuse.

(2) Check both sides of the keyswitch (iftruck is so equipped).

(3) Check both sides of the acceleratormicroswitch.

(4) Finally, check the contactor coil and con-troller KSI.

e. If the contactor coil and KSI are getting volt-age, make sure that the contactor is reallyworking, by connecting the voltmeter acrossits big terminals. There should be no measur-able voltage drop. If you see any at all, thecontactor is bad.

3. Check Potentiometer Circuitry

The following procedure applies to the basicaccelerator input configuration for these control-lers, which is a nominal 5000 ohm potentiometerconnected as a two-wire rheostat (0 ohms = fullon, 5000 ohms = full off). Some controllers aresold with other input characteristics. If your instal-lation used one of these optional inputs, find outwhat its range is and use a procedure comparableto the one blow to make sure your accelerator isworking correctly.

a. With the forks lowered, the keyswitch off, andthe battery disconnected, pull off the connec-tors going to the accelerator inputs of thecontroller. connect an ohmmeter to the twowires and measure the resistance as youmove the accelerator. The resistance at thelimits should be within these ranges:

Accelerator at Start: 4300 ohms to 4800ohms

Accelerator at Maximum: 0 ohms to 50 ohms

b. If these resistances are wrong, it is becausethe potentiometer itself is faulty or out ofadjustment, the wires to the pot are broken ormisconnected, the linkage is not moving thepot shaft through its proper travel or a switch,resistor, or the relay is defective or incorrectlywired. (See wiring diagram.)

c. While you have the accelerator wires off thecontroller, use an ohmmeter to check forshorts between these wires and the vehicle

PTW1104 6-11

frame. You should see a resistance of at least10,000 ohms. If it is lower than that, inspectthe wiring for damaged insulation or contactwith the frame. If necessary, replace thepotentiometer.

d. Push the wires back on the controller termi-nals.

e. Inspect the terminal area of the controllerclosely. Occasionally a build-up of dirt or acidresidue of a conductive nature may causeelectrical leakage between the acceleratorinput terminals and the B- or M- terminals,leading to faulty accelerator operation. Tocheck for this problem, measure the voltageat the upper pot terminal (by connecting thevoltmeter (-) lead to the controller's B- termi-nal). The keyswitch must be on and a direc-tional switch engaged for this test.

Lower Terminal

Accelerator at Start: 2.7 volts

Accelerator at Maximum: 7.0 volts

Compare your readings with these; if they aredifferent by more than a few tenths of a volt,contamination is probably the trouble.

f. Carefully clean off the terminal area of thecontroller with a cotton swab or clean ragmoistened with water, and dry thoroughly.Now test the controller to see if proper opera-tion is restored. If so, you should take stepsto prevent this from happening again. Youmust keep dirt and water from reaching theterminal area of the controller.

4. Check for controller output

a. Disconnect the wire from the direction con-tactors to the F/R contactor output of the con-troller.

b. Connect the voltmeter (+) lead to the control-ler's B+ terminal. Connect the voltmeter (-)lead to the controller's M- terminal.

c. Connect the battery, turn on the keyswitch,move the accelerator in forward, and watchthe voltmeter as you advance the accelerator.The voltmeter should read zero with theaccelerator released, and should read fullbattery voltage with the accelerator at maxi-mum. If it does not, the controller is bad andmust be replaced. If the voltmeter readings

are appropriate, release the accelerator, turnoff the keyswitch, disconnect the battery, andreconnect the wire to the direction contac-tors.

d. The next step is to measure the current in thecontroller's M- lead. If you have a means ofmeasuring this high dc current, such as ashut/meter setup or a clamp-on dc ammeter,use it. If not, we recommend that you buy anammeter of the type that is simply heldagainst the wire being tested. these are avail-able for a low cost at auto parts stores.though the accuracy of these meters is notgreat, they are adequate for this test.

e. Connect the battery, turn the keyswitch on,move the accelerator in either forward orrevere, and watch the ammeter while advanc-ing the accelerator.

f. If you see no current flowing in the M- lead,the problem is an open circuit in the motor orthe wiring between the motor and the control-ler. Check the F/R switch. If your vehicle usescontactors for reversing, check to see thatthey are operating and that their contacts areclosing. If these are okay, check the motorarmature and field for opens.

g. If you do see a high current flowing in the M-lead, but the motor does not turn, the prob-lem is either a short in the motor circuit, amiswired motor, or a short in the controller'sinternal plug diode. Test the plug diode as fol-lows:

(1) Remove power by opening the batterycircuit. Take the cable off the controller'sA2 terminal.

(2) Use an ohmmeter to check the resis-tance between the controller's A2 and B+terminals. You are testing for the pres-ence of a diode inside the controller, soswap the two leads of the ohmmeter andlook for a low resistance one way and amuch higher one the other way. If yourmeter has a diode test function, use it.

(3) If you find the diode to be shorted, thecontroller is bad and needs to bereplaced.

h. Put the A2 cable back on the controller.

i. If the plug diode is OK, there is a short in themotor circuit. An ordinary ohmmeter will notwork to find the short, because the resis-

6-12 PTW1104

tances of the motor windings are so low. Testthe motor separately if it is suspected of hav-ing a shorted winding.

j. Verify all illustrated connections and compo-nentry (Chapter 4) within the truck. If allcheck out and the source of the problem stillhas not been found, replace the controller.

6-3.4. Diagnostics And Troubleshooting (Serial Number 373234 To 376836).

The controllers provide diagnostics information toassist in troubleshooting drive system problems. Thediagnostics information can be obtained in two ways:reading the appropriate display on the programmer orobserving the fault codes issued by the Status LED.The Status LED is located on side of the controller(See Figure 7-23 for location of LED on controller).

1. LED Diagnostics

During normal operation, with no faults present,the Status LED flashes a single flash at approxi-mately 1 flash/second. If the controller detects afault, a 2-digit fault identification code is flashedcontinuously until the fault is corrected. For exam-ple, code "3,2" - welded direction contactor -appears as:

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

The codes are listed in Table 6-4. For suggestionsabout possible causes of the various faults, refer toTable 5. Troubleshooting Chart.

Operational faults - such as overtemperature - arecleared as soon as operation is brought within range.Non-operational faults - such as a throttle fault - usu-ally require the brake or keyswitch to be cycled afterthe problem is remedied.

Table 6-4. LED Codes

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

LED CODE EXPLANATION

LED Off no power or defective controller

Solid On defective controller

Single Flash o controller operational; no faults

1,2 o o o hardware fail-safe error

1,3 o o o o M- fault or motor output short

1,4 o o o o o sequencing fault (SRO)

2,1 o o o 5kΩ-0 or throttle wiper input fault

2,2 o o o o emergency reverse circuit check fault (BB wiring)

2,3 o o o o o high-pedal-disable fault (HPD)

2,4 o o o o o o throttle pot low open or shorted to B+ or B-

3,1 o o o o contactor or shunt driver overcurrent

3,2 o o o o o welded direction contactor

3,3 o o o o o o [reserved for future use]

3,4 o o o o o o o missing contactor or shunt

4,1 o o o o o low battery voltage

4,2 o o o o o o overvoltage

4,3 o o o o o o o thermal cutback

4,4 o o o o o o o o [reserved for future use]

PTW1104 6-13

2. Programmer Diagnostics

With a programmer, diagnostics and troubleshoot-ing is more direct than with the LED alone. Theprogrammer presents complete diagnostic infor-mation in plain language - no code to decipher.Faults are displayed in the Diagnostic Menu, andthe status of the controller inputs/outputs is dis-played in the Test Menu.

The following 4-step process is generally used fordiagnosing and troubleshooting an inoperative vehicle:(1) visually inspect the vehicle for obvious problems;(2) diagnose the problem, using the programmer; (3)test the circuitry with the programmer; and (4) correctthe problem. Repeat the last three steps as necessaryuntil the vehicle is operational.

Refer to Table 6-5 for suggestions covering a widerange of possible faults.

Table 6-5. Troubleshooting Chart

LED CODE PROGRAMMER LCD DISPLAY

EXPLANATION POSSIBLE CAUSE

1-2 HW FAILSAFE hardware fail-safe error 1. Controller defective

1,3 M- SHORTED M- output shorted 1. M- output shorted to ground.

2. Direction contactor not closing.

3. Direction contactor not closing fast enough.

4. Internal motor short to ground.

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

2. Wrong SRO type selected.

3. Brake or direction switch circuit open.

4. Sequencing delay too short.

2,1 THROTTLE FAULT 1 5kΩ-0 or wiper fault 1. Throttle input wire open.

2. Throttle input wire shorted to ground or B+

3. Throttle pot defective.

4. Wrong throttle type selected.

2,2 BB WIRING CHECK emergency reverse wiring fault 1. BB wire open.

2. BB check wire open.

2,3 HPD HPD sequencing fault 1. Improper seq. of KSI, brake, throttle inputs

2. Wrong HPD type selected.

3. Misadjusted throttle pot.

2,4 THROTTLE FAULT 2 Pot Low broken or shorted 1. Pot Low wire open.

2. Pot Low wire shorted.

3. Wrong throttle type selected.

6-14 PTW1104

Table 6-5. Troubleshooting Chart (Continued)

6-3.5. Adjustment of Controller Potentiometers(Prior To Serial Number 373234).

The controller has adjustable plug current, currentlimit, and acceleration rate settings. The locations ofthe adjustment pots are shown in Figure 6-4.

NOTE: Stop the truck and release the handle duringadjustment.

1. Remove the socket head screw (1/8" Allen) for theadjustment you want to make.

2. Adjust the internal potentiometer with a smallinsulated screwdriver, in order to provided thedesired performance for the identified characteris-tics.

3. Replace socket head screw and nylon sealwasher. Tighten to 8 inch-pounds maximum toprevent stripping.

6-3.6. Adjustment (Serial Number 373234 To376836).

To change a parameter using the programmer, pressthe "PROGRAM" key, and scroll down the ProgramMenu until the desired parameter is the top line of thedisplay. Press the appropriate "CHANGE VALUE" key("up" or "down") until the desired number is reached.The parameter is now set at the desired value. All pro-gramming occurs in real time. That is, the parametercan be changed while the vehicle is in operation.

Figure 6-4. Location of Adjustment Pots

Some parameters have dependencies on otherparameters. When the programmer is being used toadjust a parameter and a limit is reached, the displaywill stop changing. To see why the display has stoppedchanging, press the "MORE INFO" key. If the limit isrelated to another parameter, that information will bedisplayed; changing the value of the related parametermay allow the original parameter to be adjusted fur-ther. Otherwise, the display simply says "Max Limit" or"Min Limit".

LED CODE PROGRAMMER LCD DISPLAY

EXPLANATION POSSIBLE CAUSE

3,1 CONT DRVR OC driver output overcurrent 1. Direction contactor coil shorted.

2. Shunt field shorted.

3,2 DIR CONT WELDED welded direction contactor 1. Direction contactor stuck closed.

3,4 MISSING CONTACTOR missing contactor or shunt 1. Direction contactor coil open.

2. Direction contactor coil missing.

3. Shunt field open.

4. Wire to shunt or direction contactor open.

4,1 LOW BATTERY VOLTAGE low battery voltage 1. Battery voltage <16 volts.

2. Corroded battery or controller terminal.

3. Loose battery or controller terminal.

4,2 OVERVOLTAGE overvoltage 1. Battery voltage >33V

2. Vehicle operating with charger attached.

4,3 THERMAL CUTBACK over-/under-temp. cutback 1. Temperature >85°C or <-25°C.

2. Excessive load on vehicle.

3. Improper mounting of controller.

4. Operation in extreme environments.

R5133

PTW1104 6-15

Table 6-6. Adjustment Settings

6-3.7. Maintenance (Serial Number 373234 To376836)

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

The transistor controller is programmed at the factoryspecifically for the truck model on which it is equipped.It is important to replace the controller with the correctpreprogrammed unit to assure proper performancesettings intended for that particular truck. See Figure7-23 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.

6-3.8. Cleaning (Serial Number 373234 To 376836)

1. Remove power by disconnecting the battery.

2. 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.

3. 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.

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

6-3.9. Diagnostic History (Serial Number 373234To 376836)

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 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 contactor faults may be the result of loosewires; contactor wiring should be carefully checkedout. Faults such as HPD or overtemperature may becaused by operator habits or by overloading.

After a problem has been diagnosed and corrected,clearing the diagnostic history file is advisable. Thisallows the controller to accumulate a new file of faults.By checking the new diagnostic history file at a laterdate, you can readily determine whether the problemwas indeed completely fixed.

To clear the diagnostic history file, select:Faults->Clear Fault History.

You will be asked to confirm your actions. Use theincrement arrow (+) for yes and decrement arrow (-) tocancel and not clear the Fault History.

6-3.10.Test the Fault Detection Circuitry (SerialNumber 373234 To 376836)

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 off.

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

4. Turn the keyswitch on, release the brake andapply the throttle. The motor should not operate,and the direction contactors should not pull in.

5. Leave the keyswitch on and remove the inlinefuse wire. The vehicle status should continue toremain off.

6. Cycle the keyswitch off and on, release the brake,and apply the throttle. The vehicle should nowoperate normally.

Function Setting

Creep Speed 7

Mode 1 Plugging Current Limit Not Used

Mode 1 Acceleration Rate Not Used

Mode 2 Plugging Current Limit 80

Mode 2 Acceleration Rate 1.0

Mode 2 Maximum Speed 100

6-16 PTW1104

SECTION 7ILLUSTRATED PARTS BREAKDOWN

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

PTW1104 7-1

Figure 7-1 Control Head Assembly, Resistor

R5098

7-2 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505050-07 CONTROL HEAD 1

1 005647 . CONNECTOR 1

2 018202 . SWITCH INSULATOR 1

3 020669 . MICRO SWITCH 1


5 052956 . FLANGED BEARING 2

6 056617 . FORWARD-REVERSE DECAL 1

7 059633 . HEX LOCK NUT, 2-56 2

8 059634 . HEX LOCK NUT, 4-40 2

9 060579 . DOWEL PIN, 1/4 X 15/16 2

10 060942 . ROLL PIN, 1/8 X 1-1/4 2

11 061016 . ROLL PIN, 1/4 X 3 2

12 061200-01 . SPIROL PIN, 3/16 X 1 1

13 067416 . PAN HD SCREW, 6-32 X 1/2 4

14 068189 . RD HD SCREW, 4-40 X 1-7/8 2

15 069462 . FLAT HD SLOTTED SCREW, 6-32 X 3/4

2

16 069463 . FLAT HD SLOTTED SCREW, 6-32 X 1

2

17 069478 . PHILIPS FLAT HD SCREW, 1/4-20 X 3/4

4

18 069715 . SOCKET FLAT HD SCREW, 1/4-20 X 3/4

2

19 070486 . RD HD SLOTTED, MACHINE SCREW

2

20 072400-01 . SLOTTED HEX SCREW, 6-32 X 1/2

4

21 072415 . PAN HD SCREW, THREAD CUTTING, 4-40 X 5/8

1

22 073461 . SOCKET SET SCREW 2

23 074711 . CONNECTING ROD SPACER 1

24 075088 . RETURN SPRING 1

25 075510 . COMPRESSION SPRING 2

26 077007 . WASHER 4

27 077204 . SPLIT LOCK WASHER #6 4

28 402827 . SHAFT 1

29 402828 . CAP 2

30 402830 . BOTTOM ACCESS COVER 1

31 403358 . TUBE 2

32 402836 . SPACER 2

33 402837 . BRACKET 1

34 402839 . TUBE 1

35 402840 . CAM 1

36 402841 . HANDLE GUARD 1

37 402843 . PAD 2

38 504538-01 . SWITCH WIRE ASSEMBLY 3

39 505052 . SWITCH BRACKET 1

40 800272 . CONTROL LEVER 2

41 800273 . CONTROL HANDLE 1

42 800274 . SAFETY COVER 1

43 020697 . PUSHBUTTON SWITCH 2

44 020699 . CUTOUT SWITCH, HIGH SPEED 1

45 020776 . HORN PUSHBUTTON SWITCH 1

46 023171 . WIRE HARNESS ASSEMBLY 1

47 056618 . HIGH SPEED DECAL 1

48 056619-03 . LIFT DECAL 1

49 056619-04 . LOWER DECAL 1

50 056624 . HORN DECAL 1

51 067415 . PAN HD SCREW, 6-32 X 1/4 4

52 067416 . PAN HD SCREW, 6-32 X 1/2 4

53 068190 . PHILLIPS PAN HD SCREW 2

54 402833 . TOP COVER 1

55 402842 . SWITCH PLATE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-3

Figure 7-2 Control Head Assembly - Transistor

R5099

7-4 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505360-04 CONTROL HEAD 1

1 005652 . PIN HOUSING 1

2 505317 . RESISTOR ASSEMBLY 1

3 017580 . POTENTIOMETER 1

4 018202 . SWITCH INSULATOR 1


6 505323 . POTENTIOMETER WIRE HARNESS

1


8 052956 . FLANGED BEARING 2


10 056131 . HOSE CLAMP 1

11 056617 . FORWARD-REVERSE DECAL 1

12 057262 . POTENTIOMETER DISK 1

13 059633 . HEX LOCK NUT, 2-56 2

14 059634 . HEX LOCK NUT, 4-40 2

15 060579 . DOWEL PIN, 1/4 X 15/16 2

16 060942 . ROLL PIN, 1/8 X 1-1/4 2

17 061016 . ROLL PIN, 1/4 X 3 2

18 061200-01 . SPIROL PIN, 3/16 X 1 1

19 061750 . “E” RETAINER RING 2

20 067416 . PAN HD SCREW, 6-32 X 1/2 4

21 068180 . ROUND HD SCREW, 4-40 X 1-1/2 2

22 069462 . FLAT HD SLOTTED SCREW, 6-32 X 3/4

2

23 069463 . FLAT HD SLOTTED SCREW, 6-32 X 1

2

24 069478 . PHILIPS FLAT HD SCREW, 1/4-20 X 3/4

4

25 069715 . SOCKET FLAT HD SCREW, 1/4-20 X 3/4

2

26 070486 . PAN HD SCREW, BRASS 2

27 072400-01 . SLOTTED HEX SCREW, 6-32 X 1/2

4


1


1

30 073461 . SOCKET SET SCREW 2

31 074711 . CONNECTING ROD SPACER 1


33 075510 . COMPRESSION SPRING 2

34 077007 . WASHER 5

36 077204 . SPLIT LOCK WASHER #6 4

37 400546 . CONNECTING ROD ASSEMBLY 2

38 402827 . SHAFT 1

39 402828 . CAP 2

40 402830 . COVER 1

41 403358 . TUBE 2

42 074724 . SPACER 1

43 402836 . SPACER 2

44 402837 . BRACKET 1

45 402839 . TUBE 1

46 402840 . CAM 1

47 402841 . HANDLE GUARD 1

48 402843 . PAD 2

49 504538-01 . WIRE ASSEMBLY 5

50 505052 . SWITCH BRACKET ASSEMBLY 1

51 066052 . THUMB SCREW, 6-32 1

52 800272 . CONTROL LEVER 2

53 800273 . CONTROL HANDLE 1

54 800274 . COVER 1

55 023201 . WIRE HARNESS 1

56 020697 . PUSHBUTTON SWITCH 2

57 020699 . CUTOUT SWITCH, HIGH SPEED 1

58 020776 . HORN PUSHBUTTON SWITCH 1

59 056618 . HIGH SPEED DECAL 1

60 056619-03 . LIFT DECAL 1

61 056619-04 . LOWER DECAL 1

62 056624 . HORN DECAL 1

63 067415 . PAN HD SCREW, 6-32 X 1/4 4

64 067416 . PAN HD SCREW, 6-32 X 1/2 4

65 068190 . PHILLIPS PAN HD SCREW 2

66 402833 . TOP COVER 1

67 402842 . SWITCH PLATE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-5

Figure 7-3 Steering Arm

R5846

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505765-01 CONTROL ARM ASSY 1

1 065569 . SCREW, 7/16-14 X 2-1/4 1

2 401127 . SPACER 1

3 504364 . CLAMP ASSY 1

4 501371 . HOUSING SPRING 1

5 075060 . SPRING 1

6 059426 . NUT, HEX, 5/16-18 2

7 077210 . WASHER, LOCK, SPLIT, 5/16 2

8 060417 . PIN, COTTER 2

9 060300 . PIN, CLEVIS 1

10 052876 . BUMPER 2

11 071377 . SCREW, 10-32 X 3/4 3

12 056200 . CLEVIS 1

13 800275 . HANDLE 1

14 285302 . PIN SPRING 1

15 285303 . PIN SPRING 1

16 800204 . CLAMP 1

17 402363 . ARM, PIVOT 1

18 052925 . . BEARING FLANGED 1

19 052922 . . BEARING FLANGED 1

20 501673 . ROD, BRAKE 1

21 069478 . SCREW, PHILLIPS FLAT HEAD, 1/4-20 X 3/4

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

7-6 PTW1104

Figure 7-4 Pivot Tube Assembly

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 061716 RING, SNAP, 5/8 2

2 402452 PIN 1

3 402459 CAP 1

4 — PIVOT CAP (FIGURE 7-3) 1

5 800288 BUSHING, PIVOT 2

6 051146 BEARING, THRUST 1

7 505680-01 PIVOT TUBE 1

8 069710 SCREW, FLAT HEAD 4

9 — TRANSMISSION ASSY (FIGURE 7-6)

REF

PTW1104 7-7

Figure 7-5 Brake and Linkage

R5144

7-8 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 053109 BUSHING, LOCK 2

2 060417 PIN, COTTER, 3/32 X 3/4 5

3 053106 BUSHING, FLANGED 1

4 111104 PLATE, UPPER PIVOT 1

5 060320 PIN, CLEVIS 1

6 060321 PIN, CLEVIS 1

7 505532 WELDMENT, BRAKE ROD 1

8 503523 BRACKET 1

9 077209 WASHER, LOCK, SPLIT, 1/4 5

10 063482 SCREW 2

11 403182 BLOCK, MOUNTING 2

12 063477 SCREW, CAP, HEX HEAD 1/4-20 X 5/8)

3

13 400804 PIN 1

14 077011 WASHER, FLAT, 5/16 1

15 505232 LEVER, BRAKE 1

16 403179 PIN 1

17 800188 PIN, LINK 1

18 052821 DISC BRAKE ASSY 1

19 059421 NUT 2

20 901189 BOLT 2

21 901190 SPACER 2

22 901191 SPRING 2

23 901188 PAD, BRAKE 1

24 901198 E-RING 1

25 901197 WASHER 1

26 901196 SPRING 1

27 901192 PAD, BRAKE, WITH PIN 1

28 901195 BRACKET 1

29 901194 LEVER 1

30 901193 WASHER 1

31 077209 WASHER, LOCK, SPLIT, 1/4 2

32 — BRAKE, DISC (FIGURE 7-6) REF

33 403378 SPACER 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-9

Figure 7-6 Transmission Assembly

R5311

7-10 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505233 TRANSMISSION ASSEMBLY

1 — . DRIVE MOTOR (FIGURE 7-7) 1

2 063557 . BOLT, 5/16-18 X 1-1/4 4

3 077210 . WASHER, SPLIT, 5/16 4

4 403181 . MOTOR PLATE 1

5 065453 . SCREW, CAP, SOC HEAD10-32 X 1

3

6 057906 . KEY 1

7 505256 . DISC ASSEMBLY 1

8 — . BEARING, BALL 1

9 042132 . O-RING, 1.3 IN. DIA. 1

10 400683 . HOUSING, MOTOR BEARING 1

11 042131 . O-RING, 1.6 IN. DIA. 1

12 073517 . SEAL 1

13 505710-01 . WHEEL AND HUB ASSEMBLY (STD)

1

14 052764 . BOLT 5

15 063495 . SCREW, HEX HEAD1/4-20 X 1/2

2

16 — . PIVOT TUBE AND PLATE ASSEMBLY (FIGURE 7-4)

REF

— 901362 . GEARBOX ASSEMBLY TRANSMISSION

1

17 057237 . . GEAR, SPUR 1

18 060974 . . PIN, ROLL 1

19 026302 . . PLUG 1

20 051206 . . THRUST, BEARING, NEEDLE 2

21 051202 . . BEARING 2

22 306808 . . SPACER 1

23 057240 . . GEAR, SPUR 1

24 057258 . . GEAR AND SHAFT 1

25 051216 . . BEARING, NEEDLE 1



28 057241 . . GEAR 1

29 053031 . . BEARING, THRUST 1

30 251204 . . BEARING NEEDLE 1

31 051203 . . BEARING NEEDLE 2


33 050711 . . SHAFT 1



36 073516 . . SEAL 1


38 — . . NOT USED

39 057908 . . KEY 1

40 057242 . . GEAR, SPUR 1

41 061731 . . RING, SNAP, EXT, 1-3/8 1

42 036115 . . GASKET 1

43 800184 . . COVER 1

44 060609 . . PIN 2

45 063482 . . SCREW, 1/4-20 X 1-1/4 14

46 077209 . . WASHER, LOCK, 1/4 14

47 026310 . . PLUG 1

48 076702 . . VENT, TRANSMISSION 1

49 800176 . . HOUSING, TRANSMISSION 1

50 057238 . . GEAR, SPUR 1

51 057909 . . KEY 3


53 077208 . . WASHER, LOCK, 3/16 3

54 060609 . . PIN 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-11

Figure 7-7 Drive Motor Assembly

R5312


INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 016046 MOTOR, DRIVE 1

1 901264 . COIL SET, FIELD 1

2 901265 . ARMATURE 1

3 901266 . BEARING, COMMUTATOR END 1

4 900450 . BRUSH (SET OF TWO) 1

5 901451 . SPRING, BRUSH (SET OF TWO) 1

6 901267 . HEAD, COMMUTATOR END 1

7 901268 . TERMINAL KIT 1

8 — . WASHER, LOCK, 1/4 4

9 — . SCREW, FILLISTER HEAD, 10-32 X 3/4

4

10 901269 . HOLDER, BRUSH 1

11 — . SCREW, PLOE SHOE, 3/8-16 X 1/2

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

7-12 PTW1104

Figure 7-8 Drive Motor Assembly

R6109


INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 016052 MOTOR, DRIVE 1

1 907176 . ARMATURE 1

2 901266 . BEARING, COMMUTATOR END 1

3 — . FIELD COILS 1

4 — . POLE SHOES 2

5 — . FIELD RING 1

6 907177 . BRUSH SET 1

7 907178 . SPRING SET 1

8 907179 . BRUSH HOLDER 1

9 907180 . HEAD, COMMUTATOR 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-13

Figure 7-9 Base and Frame

R5313

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 505528 COVER 1

2 059925-01 NUT, U-CLIP 2

3 063482 SCREW, HEX HEAD, 1/4-20 X 1-1/4

2

4 077209 WASHER, SPLIT, LOCK, 1/4 12

5 403694 COVER, LH 1

6 070477 SCREW, RD HD PHILLIPS, 1/4-20 X 5/8

8

7 077030 WASHER, FLAT NO. 1/4 8

8 403695 COVER, RH 1

9 077031 WASHER, FLAT NO. 1/4 2

10 059421 NUT, HEX, 1/4-20 2

11 505702-01 FRAME, POWER SECTION 1

12 060965 PIN, ROLL 2

INDEXNO.

PARTNO. PART NAME

NO.REQD.

7-14 PTW1104

NOTES

PTW1104 7-15

Figure 7-10 Fork Section Assembly

R5314

7-16 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 505706-01 FORK SECTION WELDMENT(48” LG X 27 W)

1


1


1


1

2 075085 SPRING, EXTENSION 4

3 061200-02 PIN, SPIROL 2

4 402432 SHAFT, PILOT 4

5 061200-04 PIN, SPIROL 1

6 505709 WHEEL ASSY, POLY 2

7 051136 . BEARING, BALL 2

8 077033 WASHER, FLAT 4

9 505708 HOUSING, WHEEL 2

10 052948-03 . BEARING, SLEEVE 2

11 403687 SHAFT, AXLE 2

12 402431-01 SHAFT 2


14 505614-01 ROD END, FRONT (48” LG FORK) 2




16 505615-01 ROD END, REAR 2


18 059444 NUT, HEX 2

19 077215 WASHER, LOCK 2

20 402501 TURNBUCKLE 2

21 075085 SPRING, EXTENSION 4

22 402431-02 SHAFT 4

23 061200-01 PIN, SPIROL 6

24 505534 PIVOT, WELDMENT 2

25 052948-02 BEARING SLEEVE 4

26 504708 ROLLER ASSY 2


28 403511-01 SHAFT, PIVOT 2

29 403505 ROLLER 4

30 053012 WASHER, THRUST, 3/32” THK AR




INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-17

Figure 7-11 Hydraulic System Installation

R5324

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 063603 SCREW, HEX HEAD CAP 2



4 065476 SCREW, HEX HEAD CAP, 1/4-20 X 1/2

1

5 077209 WASHER, LOCK, 1/4 1


7 403699 GUIDE, CYLINDER 1

8 504732-01 HOSE ASSY 1

9 026922 ADAPTER, STRAIGHT 1

10 505582 CYLINDER ASSY, HYD(SEE FIGURE 7-13)

1



13 505529 MOUNT, CYLINDER 1

14 016594 PUMP AND MOTOR ASSY(SEE FIGURE 7-12)

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

7-18 PTW1104

Figure 7-12 Pump, Motor and Reservoir Assembly

R4356

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 901432 CAP/BRUSH KIT 1

2 901433 24V MOTOR 1

3 020715 24V SOLENOID 1

4 901434 MOTOR ADAPTER 1

5 048133 SOLENOID RELEASE VALVE 1

6 901435 FLOW REGULATOR 1

7 901436 CHECK VALVE 1

8 901437 ADAPTER-PUMP-RES KIT 1

9 901438 O-RING 1

10 901439 COUPLING 1

11 901440 FILTER 1

12 901441 RESERVOIR 1

13 026703 ELBOW 1

14 901442 RELIEF VALVE ASSY 1

15 076701 BREATHER PLUG 1

16 025535 ELBOW, 9/16 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-19

Figure 7-13 Hydraulic Cylinder Assembly

R5325

PACKING KIT901498 CONTAINS:

ITEM QTY1 12 14 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505582 CYLINDER ASSEMBLY,HYDRAULIC

REF

1 049514 * . RING, WIPER 1

2 043134 * . SEAL, HEAD 1

3 — . HEAD, CYLINDER 1

4 042153 * . O-RING 1

5 — . ROD 1

6 — . CYLINDER WELDMENT 1

* INCLUDED IN PACKING KIT, PN 901498, FOR ONE CYLINDER

INDEXNO.

PARTNO. PART NAME

NO.REQD.

7-20 PTW1104

Figure 7-14 Storage and Batteries and Connector

R5315

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 005450 HANDLE, BATTERY CONNECTOR 1

2 505549 CABLE ASSEMBLY, BATTERY 1

3 070476 SCREW, MACHINE, RD HEAD 1


5 056139 CLAMP 1

6 505548 CABLE ASSEMBLY, BATTERY JUMPER

1

7 003217 BATTERY, STORAGE, 12V 155 AH, DRY

2

7 003217-01 BATTERY, STORAGE, 12V 200 AH, WET

2

7 003149 BATTERY, STORAGE, 12V 200 AH, DRY

2

7 003148 BATTERY, STORAGE, 12V 200 AH, WET

2

8 056133 WIRE TIE A/R

9 505598-02 * SPACER INSTL., BATTERY, 155 AH

1

9 505598-03 * SPACER INSTL., BATTERY, 200 AH

1

* NOT SHOWN

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-21

Figure 7-15 Quick Disconnect Cable Installation

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505634 QUICK DISCONNECT CABLE KIT

1 505622 CONNECTOR ASSEMBLY BATTERY

4

2 505633 CONNECTOR ASSEMBLY BATTERY

1

3 505649 CORD ASSY-CHARGING, EXTERNAL

1

R5695

1

1

1

13

2

7-22 PTW1104

Figure 7-16 Horn Installation

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 059421 NUT, HEX 1



4 504096 SUPPRESSOR, SPIKE (TRANSISTOR TRUCKS ONLY)

1

5 009602 HORN, WARNING, 24V 1

R5320

PTW1104 7-23

Figure 7-17 Electrical Installation, Resistor

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 023224 HARNESS ASSEMBLY, PUMP 1

2 504364 NUT AND CLAMP ASSEMBLY 2

3 023228 CABLE ASSEMBLY, PIVOT TUBE 1

4 069478 SCREW, MACHINE, FLAT HEAD 2

5 056141 CLAMP, CABLE 2


7 059429 NUT, HEX 4

8 505547 CABLE ASSEMBLY, DEADMAN 1

9 005405 RELIEF, STRAIN 1

10 020729 SWITCH, DEADMAN 1

11 505544 PANEL ASSEMBLY CONTACTOR (SEE FIGURE 7-21)

1

R5316

7-24 PTW1104

Figure 7-18 Electrical Installation, Transistor

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 023224 HARNESS ASSEMBLY, PUMP 1

2 504364 NUT AND CLAMP ASSEMBLY 2

3 023223 CABLE ASSEMBLY, PIVOT TUBE 1

4 069478 SCREW, MACHINE, FLAT HEAD 2

5 056141 CLAMP, CABLE 2


7 059429 NUT, HEX 4

8 505547 CABLE ASSEMBLY, DEADMAN 1



11 505544 PANEL ASSEMBLY CONTACTOR (SEE FIGURE 7-21)

1

12 504116 SPIKE SUPPRESSOR ASSEMBLY 1

13 504097 SPIKE SUPPRESSOR ASSEMBLY 1

R5318

PTW1104 7-25

Figure 7-19 PTW Battery Charger Installation

R5516

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 021204 TERMINAL, SLIP ON 1

2 077211 WASHER, LOCK, 3/8 SPLIT 1

3 059429 NUT, HEX, 3/8-16 1

4 059421 NUT, HEX, 6-32 1

5 021206 TERMINAL, RING 1

6 505675-02 WIRE, ELECTRICAL A/R

7 403688 SHIM, BATTERY CONNECTOR 1

8 077209 WASHER, LOCK, 1/4 SPLIT 3

9 065476 SCREW, HEX HD 1

10 063482 SCREW, MACHINE 2

11 021718 TERMINAL, SLIP-ON 3

12 505674-01 FUSE HOLDER ASY 1

13 008910 FUSE, 15 AMP 1


15 004978 CHARGER, 120 VAC 1

15 004980 CHARGER, 240 VAC 1

16 901603 . CIRCUIT BOARD WITH HEAT SINK

1

17 901604 . CIRCUIT BREAKER 1

18 900379 . INDICATOR LIGHT (PART OF ITEM 15)

1

19 005802 CORD, CHARGER120 VAC, 10 FT

1

19 505712 CORD, CHARGER240 VAC, 10 FT

1

20 505597 CONNECTOR ASSEMBLY 1

21 015609 AMMETER 1

22 005433 CONNECTOR, INLINE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

7-26 PTW1104

NOTES

PTW1104 7-27

Figure 7-20 Contactor Panel Assembly, Resistor

R5317

7-28 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505544 PANEL ASSEMBLY, RESISTOR REF

1 504611-28 . CABLE ASSEMBLY,F1 AND F2

2

2 504611-18 . CABLE ASSEMBLY, TO MAIN FUSE

1

3 504611-26 . CABLE ASSEMBLY, TO PUMP POSITIVE

1

4 403549 . BUSS BAR 2

5 403548 . BUSS BAR 2

5 074805 . SPINDLE 4

6 005667 . SOLENOID-CONTACTOR, 24V DIRECTIONAL

2

7 070478 . SCREW, MACHINE, RD HEAD 9

8 504611-27 . CABLE ASSEMBLY, A2 1

9 008904 . FUSE HOLDER 1

10 008910 . FUSE, 15 A 1

11 077203 . WASHER, LOCK 1

12 068179 . SCREW 1

13 056504 . DECAL, 15 A FUSE 1

14 005668 . SOLENOID - CONTACTOR 24V SPEED

2

15 504611-31 . CABLE ASSEMBLY, TO RESISTOR

1

16 505596-01 . TIME DELAY ASSEMBLY 1

17 056121 . CLAMP 1

18 071376 . SCREW 4

19 077207 . WASHER, LOCK 6

20 059416 . NUT, HEX 5


22 403550 . BUS BAR 1

23 075623-01 . STUD 2

24 — NOT USED

25 075623-06 . STUD 2

26 403547 . PANEL, CONTACTOR 1


1

28 402256 . MOUNT RESISTOR 2

29 018911 . RESISTOR 1


31 504611-33 . CABLE ASSEMBLY, PUMP NEG 1


1

33 077007 . WASHER, FLAT 3

34 — NOT USED

35 059421 . NUT, HEX 10

36 077209 . WASHER, LOCK 12

37 077031 . WASHER, FLAT 2

38 010614 . STANDOFF, INSULATOR 2

39 056562 . DECAL, FUSE 120 A 1

40 008918 . FUSE, 120 1

41 070489 . SCREW, MACHINE 2

42 077105 . WASHER, BRONZE 4

43 505546-01 . CONNECTOR ASSEMBLY, BATTERY

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-29

Figure 7-21 Contactor Panel Assembly, Transistor

R5319


7-30 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505553 PANEL ASSEMBLY CONTACTOR, TRANSISTOR

REF

1 005996 . DIODE ASSEMBLY 2

2 504611-28 . CABLE ASSEMBLY, F1 AND F2 2

3 403549 . BUSS BAR 2

4 403548 . BUSS BAR 2

5 005667 . SOLENOID-CONTACTOR, 24V - DIRECTIONAL

2

6 504611-36 . CABLE ASSEMBLY CONTACTOR TO CONTROLLER

1

7 008904 . FUSEHOLDER 1

8 008910 . FUSE, 15A 1

9 077203 . WASHER, LOCK 3


11 056504 . DECAL, FUSE, 15 A 1

12 504611-24 . CABLE ASSEMBLYCONTACTOR TO CONTROLLER

1


14 504611-04 . CABLE ASSEMBLY, TO PUMP NEGATIVE/POS

2

15 075623-01 . STUD 2


17 075623-06 . STUD 2

18 403547 . PANEL, CONTACTOR 1


20 077209 . WASHER, LOCK 11

21 059421 . NUT, HEX 9

22 010610 . PAD, INSULATOR 1

23 505320 . DIODE ASSEMBLY 1

24 077007 . WASHER, FLAT 2

25 068177 . SCREW, MACHINE, RH HEAD 2

26 505321 . SUPPRESSOR ASSEMBLY 1

27 018409-02 . RELAY, 24V 1

28 056113 . WIRE TIE 3

29 056111 . WIRE TIE 2


31 005467-02 . CONTROLLER, SPEED 1

32 504611-31 . CABLE ASSEMBLY, MAINFUSE TO CONTROLLER

1

33 — . NOT USED

34 008918 . FUSE, 120 A 1

35 056562 . DECAL, FUSE, 120 A 1

36 070489 . SCREW, MACHINE, RD HEADBRASS

2

37 010614 . STANDOFF, INSULATOR 2

38 077105 . WASHER, BRONZE 4


40 505546-02 . CONNECTOR ASSEMBLY,BATTERY

1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-31

Figure 7-22 Contactor Panel Assembly, E Rated Transistor

R4133


7-32 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

— 505430 PANEL ASSEMBLY CONTACTOR, TYPE E TRANSISTOR

REF

1 005467-02 . 24V SPEED CONTROLLER 1

2 005667 . 24V CONTACTOR, FWD/REV 2

3 018409-02 . 24V FLANGE MOUNTED RELAY 1

4 505424 . TRANSISTOR PANEL 1

5 068177 . SCREW-RD HD, #5-40 X 3/8 4

6 077203 . WAHSER-LOCK, SPLIT, #5 5

7 077007 WASHER 6

8 505321 SUPPRESSOR ASSY 1

9 070475 SCREW-PH RD HD, 1/4-20 X 3/8 4

10 077209 WASHER-LOCK, SPLIT, 1/4 6

11 505320 DIODE ASSY 1

12 010610 PAD-INSUL, DIODE 1

13 401181 BUSSBAR 2

14 070491 WASHER 4

15 077205 WASHER-LOCK, SPLIT, #8 4

16 077032 WASHER, 3/16 X 1/2 X 13 GA 4

17 008910 FUSE-15 AMP 1

18 008904 FUSEHOLDER FOR 008910 (15AMP FUSE)

1

19 068179 SCREW-RD HD, #5-40 X 5/8 1

20 056504 DECAL-FUSE, 15A 1

21 023215 BATTERY CONNECTOR ASSY 1

22 005422 CONNECTOR-INLINE, INSUL 2

23 008918 FUSE-120 AMP 1

24 056562 DECAL-FUSE 120 AMP 1

25 010614 STANDOFF-INSULATOR 2

26 077105 WASHER-BRONZE 4

27 070489 SCREW-RD HD, BRASS SLOTTED

2

28 069477 SCREW-PH, FL HD, 1/4-20 X 1/2 2

29 063552 SCREW-HEX CAP, 5/16-18 X 5/8 2

30 059426 NUT-HEX, 5/16-18 4

31 077210 WASHER-LOCK, SPLIT, 5/16 4

32 063553 SCREW-HEX CAP, 5/16-18 X 3/4 2

33 005976 DIODE 2

34 010613 TUBING-INSULATING A/R

35 505447 CONNECTOR ASSY, BATTERY 1

36 504611-18 CABLE ASSEMBLY (M-) 1

37 504611-19 CABLE ASSEMBLY (A2) 1

38 504611-20 CABLE ASSEMBLY (POS) 1

39 504611-22 CABLE ASSEMBLY 1






INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-33

Figure 7-23 Contactor Panel Assembly, E Rated Transistor

R6130


7-34 PTW1104

INDEXNO.

PARTNO. PART NAME

NO.REQD.

505903 PANEL ASSY., ELEC. REF

1 403837 PANEL WELDMENT 1

2 907200-02 CONTROLLER - SPEED, 24V,PREPROGRAMMED

2

3 070478 SCREW - PH RD HD, 1/4-20 x 3/4 3

4 077209 WASHER - LOCK, SPLIT, 1/4 10

5 059421 NUT - HEX, 1/4-20 8

6 070477 SCREW - PH RD HD, 1/4-20 x 5/8 3

7 005996 DIODE ASY - CONTACTOR 2

8 505546-02 CONNECTOR ASSY, BATTERY 1

9 077105 WASHER, BRASS 4

10 070489 SCREW - RH HD, BRASS, SLOTTED

2

11 008918 FUSE - 120 AMP 1

12 023256 HARNESS ASSY - PANEL 1

13 056562 DECAL - FUSE 120 AMP 1

14 010614 STANDOFF - INSULATOR 2

15 063553 SCREW - HEX CAP, 5/16-18 X 3/4

4

16 077210 WASHER - LOCK, SPLIT, 5/16 4

17 059426 NUT-HEX, 5/16-18 4

18 056504 DECAL - FUSE 15 AMP 1

19 068179 SCREW - PH RD HD, #5-40 x 5/8 1

20 077203 WASHER - LOCK, SPLIT, #5 1

21 008910 FUSE - 15 AMP 1

22 008904 FUSE HOLDER 1

23 005667 CONTACTOR - DIRECTIONAL,SOLENOID, 24v

2

24 403548 BUS BAR 2

25 403549 BUS BAR 2

26 075623-06 STUD - PRESS IN, 1/4-20 X 1-1/4 2

27 075623-01 STUD - PRESS IN, 1/4-20 X 1/2 2

28 504611-27 CABLE ASY 1

29 504611-04 CABLE ASY 2

30 504611-36 CABLE ASY 1

31 504611-31 CABLE ASY 1

32 504611-44 CABLE ASY 1

33 504611-28 CABLE ASY 2

34 504611-34 CABLE ASY 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-35

Figure 7-24 Battery Discharge Indicator - Option Figure 7-25 Key Switch - Option

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 010617-02 INDICATOR, BATTERYDISCHARGE, 24V

1


3 056111 STRAP, TIEDOWN, ELECTRICAL 2

4 021207 TERMINAL, LUG, RING 2

5 403696 PANEL (NOT SHOWN) 1

R5328

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 020725 SWITCH, KEY 1

2 021203 TERMINAL, RING NO. 10 2


4 005422 CONNECTOR, TAB 2


R5332

7-36 PTW1104

Figure 7-26 Cold Conditioning Package Installation - Option

R5329

INDEXNO.

PARTNO. PART NAME

NO.REQD.



3 023135 CABLE ASSY, DEADMAN REF

4 056491 DECAL, COLD CONDITIONING 1

5 068186 SCREW 2

6 059632 NUT, LOCK 2

7 403372 INSULATOR 2

8 020736 SWITCH, THERMAL 1

9 400044 BRACKET 1

10 400544 BRACKET, RESISTOR MTG 1

11 018909 10 OHM, 20 WATT HEAT RESITOR

2

12 — NOT USED

13 018214 INSULATOR 1

14 072400-01 SCREW 2


16 077007 WASHER 2

17 402829 BRACKET 1

18 005643 TERMINAL, CONTACT PIN 1

19 005649 SPLICE 1

20 055750 * GREASE A/R

20 055753 ** GREASE A/R

21 055779 * HYDRAULIC OIL A/R

21 055784 ** HYDRAULIC OIL A/R

22 055780 * TRANSMISSION OIL A/R

22 055790 ** TRANSMISSION OIL A/R

A/R - AS REQUIRED

* FOR INTERMITTENT OPERATION BELOW 32° F.** FOR CONTINUOUS OPERATION BELOW 32° F.

INDEXNO.

PARTNO. PART NAME

NO.REQD.

PTW1104 7-37

Figure 7-27 Hourmeter Installation - Option

R5330

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 056111 WIRE TIE 3

2 068179 SCREW, MACHINE, ROUND HEAD

3

3 015604 HOURMETER 1

4 005649 SPLICE, CONNECTOR 2

5 005626 PIN, CONTACT 3

6 005647 HOUSING, PIN 1

7 010610 PAD, INSULATING 1

8 005993 DIODE ASSEMBLY 2

9 077203 WASHER, LOCK, SPLIT, NO. 5 3

10 059410 NUT, HEX 5-40 3





INDEXNO.

PARTNO. PART NAME

NO.REQD.

7-38 PTW1104

Figure 7-28 Load Backrest - Option

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 505563-01 BACKREST WELDMENT, 48” HIGH

1


3 077213 WASHER 4

R5331

PTW1104 7-39

Figure 7-29 Caster

R5641

INDEXNO.

PARTNO. PART NAME

NO.REQD.

1 069716 SCREW, 1/2-13 X 1-1/4 8

2 — NOT USED

3 — NOT USED

4 402365 SHIM A/R

5 — NOT USED

— 504620-01 CASTER ASSEMBLY 2

6 069715 . SCREWHOUSING, PIN 1

7 402327 . CLAMP 1

8 402289 . RACE, BEARING 2

9 051404 . HOUSING, BEARING 16

10 402292 . HOUSING, BEARING 1

11 402288 . BASE, CASTER 1

12 075075 . SPRING 2

13 504621 . ARM WELDMENT 1

14 402291 . AXLE 1

15 025713 . FITTING, LUBE 1

16 051154 . BEARING, THRUST 2

17 051152 . BEARING 2

18 078263 . WHEEL 1

19 059645 . NUT, LOCK 1

20 077210 . LOCKWASHER, 5/16 2

21 063553 . SCREW, 5/16-18 X 3/4 2

22 402290 . SHAFT 1

23 053041-01 . BUSHING 2

24 061004 . PIN, ROLL 1

25 025702 . FITTING, LUBE 1

INDEXNO.

PARTNO. PART NAME

NO.REQD.

7-40 PTW1104

Big Joe Manufacturing Company

Documents

PTW-40 SERIES - Big Lift, LLC Support Site for Big Joe ... · Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901354 REV. A 1104 Manual Price $35.00 PTW-40 SERIES