Manual Price $35.

00

PTW-40 SERIES
SELF-PROPELLED, PALLET
LIFT TRUCK
Serial Number 345621, 345718,
345875 TO 376836
Operation
Maintenance
Repair Parts List

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

Section Page Section Page

1 DESCRIPTION ............................................................1-1 4-6. BASE, FRAME, AND FORK SECTION. ........ 4-17
1-1. INTRODUCTION. ............................................1-1 4-6.1. GENERAL...................................................... 4-17
1-2. GENERAL DESCRIPTION...............................1-1 4-6.2. LOAD WHEEL REPLACEMENT. .................. 4-17
1-3. NAMEPLATE....................................................1-1 4-6.3. FRAME ASSEMBLY: FORK SECTION
1-4. SAFETY FEATURES. ......................................1-2 AND LIFT LINKAGE REPAIR AND
1-5. OPTIONS. ........................................................1-2 REPLACEMENT. ........................................... 4-18
4-7. ELECTRICAL................................................. 4-20
2 OPERATION ...............................................................2-1 4-7.1. BATTERY REMOVAL AND REPLACEMENT 4-20
2-1. GENERAL. .......................................................2-1 4-7.2. BATTERY CABLE ASSEMBLIES
2-2. OPERATING PRECAUTIONS. ........................2-1 REPLACEMENT. ........................................... 4-20
2-3. GENERAL CONTROL OPERATION................2-1 4-7.3. RESISTOR/CONTACTOR PANEL. ............... 4-20
2-4. DRIVING AND STOPPING PROCEDURES. ...2-1 4-7.4. TRANSISTOR/CONTACTOR PANEL -
2-5. BELLY-BUTTON SWITCH. ..............................2-3 TRANSISTOR TRUCKS. ............................... 4-23
2-6. STEERING ARM RETURN SPRING. ..............2-3 4-7.5. HORN REPLACEMENT. ............................... 4-27
2-7. LIFT AND LOWER CONTROLS. .....................2-3 4-7.6. BATTERY CHARGER (Figure 4-24).............. 4-27
2-8. LOADING AND UNLOADING. .........................2-3 4-7.7. WIRE HARNESS TESTING. ......................... 4-27
2-9. PARKING. ........................................................2-3 4-7.8. WIRING. ........................................................ 4-27
3 MAINTENANCE ..........................................................3-1 4-8. HYDRAULICS................................................ 4-36
3-1. GENERAL. .......................................................3-1 4-8.1. LINE AND FITTING REPLACEMENT. .......... 4-36
3-2. OPERATOR DAILY CHECKS..........................3-1 4-8.2. HYDRAULIC PUMP, MOTOR, AND
3-3. MONTHLY AND QUARTERLY CHECKS. .......3-2 RESERVOIR ASSEMBLY. ............................ 4-38
3-4. BATTERY CARE. .............................................3-2 4-8.3. LIFT CYLINDER REMOVAL.......................... 4-38
3-4.1. GENERAL. .......................................................3-2 4-8.4. LIFT CYLINDER REPAIR. ............................. 4-39
3-4.2. BATTERY REMOVAL. .....................................3-2 4-8.5. HYDRAULIC PRESSURE ADJUSTMENT. ... 4-39
3-4.3. TESTING AND CHARGING BATTERY. ..........3-2 4-9. DECALS AND TRIM. ..................................... 4-39
3-5. LUBRICATION. ................................................3-3 4-9.1. PAINTING REQUIREMENTS. ....................... 4-39
4-9.2. DECALS AND PLATES. ................................ 4-39
4 ADJUSTMENT AND REPAIR .....................................4-1
4-1. GENERAL. .......................................................4-1 5 OPTIONS.................................................................... 5-1
4-2. PART NUMBER IDENTIFICATION..................4-1 5-1. BATTERY DISCHARGE INDICATOR. ............ 5-1
4-3. STEERING ARM AND CONTROL HEAD. .......4-1 5-1.1. BATTERY DISCHARGE INDICATOR
4-3.1. BELLY-BUTTON SWITCH ADJUSTMENT. .....4-1 REPLACEMENT. ............................................. 5-1
4-3.2. POTENTIOMETER TESTING AND 5-2. HOURMETER.................................................. 5-1
ADJUSTMENT (TRANSISTOR UNITS 5-2.1. HOURMETER REPLACEMENT...................... 5-1
ONLY). .............................................................4-1 5-3. KEYSWITCH. .................................................. 5-1
4-3.3. RESISTOR CONTROL HEAD SWITCH 5-4. COLD CONDITIONING PACKAGE................. 5-1
REPLACEMENT...............................................4-2 5-5. LOAD BACKREST........................................... 5-2
4-3.4. TRANSISTOR CONTROL HEAD SWITCH 5-6. CASTER .......................................................... 5-2
REPLACEMENT...............................................4-5 6 TROUBLESHOOTING................................................ 6-1
4-3.5. STEERING ARM. .............................................4-6 6-1. TROUBLESHOOTING CHART. ...................... 6-1
4-3.6. ELECTRICAL CONTROL CABLE 6-2. CONTACTOR AND SWITCH
REPLACEMENT...............................................4-8 TROUBLESHOOTING..................................... 6-3
4-4. BRAKES. ........................................................ 4-10 6-2.1. CONTACTOR TESTING. ................................ 6-3
4-4.1. ADJUSTMENT. .............................................. 4-10 6-2.2. SWITCH TESTING. ......................................... 6-3
4-4.2. REPLACEMENT OF BRAKE PADS............... 4-10 6-3. TRANSISTOR CONTROLLER
4-4.3. REPLACEMENT OF DEAD-MAN SWITCH. .. 4-12 TROUBLESHOOTING..................................... 6-6
4-5. TRANSMISSION, DRIVE MOTOR, DRIVE 6-3.1. CIRCUIT OPERATION. ................................... 6-6
WHEEL, AND PIVOT TUBE ASSEMBLY. ..... 4-12 6-3.2. GENERAL CHECKOUT (SERIAL NUMBER
4-5.1. TRANSMISSION AND PIVOT TUBE 373234 TO 376836)......................................... 6-9
ASSEMBLY REMOVAL.................................. 4-12 6-3.3. TROUBLESHOOTING (PRIOR TO SERIAL
4-5.2. TRANSMISSION INITIAL DISASSEMBLY..... 4-12 NUMBER 373234). ........................................ 6-10
4-5.3. DRIVE AXLE REMOVAL................................ 4-12 6-3.4. DIAGNOSTICS AND TROUBLESHOOTING
4-5.4. DRIVE MOTOR/BRAKE ASSEMBLY (SERIAL NUMBER 373234 TO 376836). ...... 6-13
REMOVAL. ..................................................... 4-13
4-5.5. DRIVE MOTOR SERVICING. ........................ 4-13

PTW1104 i
 TABLE OF CONTENTS (Cont)

Section Page Section Page

6-3.5. ADJUSTMENT OF CONTROLLER 6-3.8. CLEANING (SERIAL NUMBER
POTENTIOMETERS (PRIOR TO SERIAL 373234 TO 376836) ....................................... 6-16
NUMBER 373234). ........................................ 6-15 6-3.9. DIAGNOSTIC HISTORY (SERIAL NUMBER
6-3.6. ADJUSTMENT (SERIAL NUMBER 373234 TO 376836) ....................................... 6-16
373234 TO 376836). ...................................... 6-15 6-3.10.TEST THE FAULT DETECTION
6-3.7. MAINTENANCE (SERIAL NUMBER CIRCUITRY ................................................... 6-16
373234 TO 376836)....................................... 6-16
7 ILLUSTRATED PARTS BREAKDOWN ...................... 7-1

LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 PTW-40 LIFT TRUCK ................................. 1-1 4-23 HORN INSTALLATION ............................. 4-28
2-1 STEERING ARM CONTROLS .................... 2-2 4-24 BATTERY CHARGER INSTALLATION .... 4-28
2-2 BRAKE ........................................................ 2-2 4-25 WIRING DIAGRAM -
3-1 LUBRICATION DIAGRAM .......................... 3-4 RESISTOR TRUCKS ................................ 4-30
4-1 BELLY-BUTTON SWITCH AND 4-26 WIRING DIAGRAM -
POTENTIOMETER ADJUSTMENT ............ 4-2 TRANSISTOR TRUCKS ........................... 4-31
4-2 CONTROL HEAD ASSEMBLY - 4-27 WIRING DIAGRAM -
RESISTOR .................................................. 4-3 TRANSISTOR TRUCKS ........................... 4-32
4-3 CONTROL HEAD ASSEMBLY - 4-28 WIRING DIAGRAM -
TRANSISTOR ............................................. 4-4 TRANSISTOR TRUCKS ........................... 4-34
4-4 STEERING ARM ......................................... 4-7 4-29 HYDRAULIC SYSTEM INSTALLATION ... 4-36
-5 ELECTRICAL CONTROL CABLE 4-30 PUMP, MOTOR AND RESERVOIR
REPLACEMENT ......................................... 4-9 ASSEMBLY ............................................... 4-37
4-6 BRAKE ADJUSTMENT............................. 4-10 4-31 HYDRAULIC SYSTEM INSTALLATION ... 4-38
4-7 DEAD-MAN SWITCH................................ 4-10 6-1 CONTACTOR TESTING ............................. 6-4
4-8 BRAKE AND LINKAGE............................. 4-11 6-2 SWITCH TESTING ..................................... 6-5
4-9 PIVOT CAP AND TUBE INSTALLATION . 4-13 6-3 FULL FEATURE ELECTRONIC MOTOR
4-10 TRANSMISSION ASSEMBLY .................. 4-14 CONTROLLER............................................ 6-7
4-11 DRIVE MOTOR ASSEMBLY .................... 4-15 6-4 LOCATION OF ADJUSTMENT POTS ...... 6-15
4-12 DRIVE MOTOR ASSEMBLY .................... 4-15 7-1 CONTROL HEAD ASSEMBLY,
4-13 POWER SECTION FRAME AND RESISTOR .................................................. 7-2
MOTOR COMPARTMENT COVER.......... 4-16 7-2 CONTROL HEAD ASSEMBLY -
4-14 FORK SECTION ASSEMBLY ................... 4-17 TRANSISTOR ............................................. 7-4
4-15 PULL ROD ADJUSTMENT DETAILS ....... 4-19 7-3 STEERING ARM ......................................... 7-6
4-16 STORAGE BATTERIES AND 7-4 PIVOT TUBE ASSEMBLY .......................... 7-7
CONNECTORS......................................... 4-21 7-5 BRAKE AND LINKAGE ............................... 7-8
4-17 ELECTRICAL INSTALLATION - 7-6 TRANSMISSION ASSEMBLY .................. 7-10
RESISTOR TRUCKS ................................ 4-21 7-7 DRIVE MOTOR ASSEMBLY .................... 7-12
4-18 CONTACTOR PANEL ASSEMBLY - 7-8 DRIVE MOTOR ASSEMBLY .................... 7-13
RESISTOR TRUCKS ................................ 4-22 7-9 BASE AND FRAME .................................. 7-14
4-19 ELECTRICAL SYSTEM INSTALLATION - 7-10 FORK SECTION ASSEMBLY................... 7-16
TRANSISTOR TRUCKS ........................... 4-23 7-11 HYDRAULIC SYSTEM INSTALLATION ... 7-18
4-20 CONTACTOR PANEL ASSEMBLY - 7-12 PUMP, MOTOR AND RESERVOIR
TRANSISTOR TRUCKS ........................... 4-24 ASSEMBLY ............................................... 7-19
4-21 CONTACTOR PANEL ASSEMBLY - 7-13 HYDRAULIC CYLINDER ASSEMBLY ...... 7-20
TRANSISTOR TRUCKS ........................... 4-25 7-14 STORAGE AND BATTERIES AND
4-22 CONTACTOR PANEL ASSEMBLY - CONNECTOR ........................................... 7-21
TRANSISTOR TRUCKS ........................... 4-26 7-15 QUICK DISCONNECT CABLE
INSTALLATION......................................... 7-22

ii PTW1104
 LIST OF ILLUSTRATIONS (Cont)

Figure Page Figure Page

7-16 HORN INSTALLATION ............................. 7-23 7-22 CONTACTOR PANEL ASSEMBLY,
7-17 ELECTRICAL INSTALLATION, E RATED TRANSISTOR........................... 7-32
RESISTOR ................................................ 7-24 7-23 CONTACTOR PANEL ASSEMBLY,
7-18 ELECTRICAL INSTALLATION, E RATED TRANSISTOR........................... 7-34
TRANSISTOR ........................................... 7-25 7-24 BATTERY DISCHARGE INDICATOR -
7-19 PTW BATTERY CHARGER OPTION..................................................... 7-36
INSTALLATION ........................................ 7-26 7-25 KEY SWITCH - OPTION ........................... 7-36
7-20 CONTACTOR PANEL ASSEMBLY, 7-26 COLD CONDITIONING PACKAGE
RESISTOR ................................................ 7-28 INSTALLATION - OPTION ........................ 7-37
7-21 CONTACTOR PANEL ASSEMBLY, 7-27 HOURMETER INSTALLATION - OPTION 7-38
TRANSISTOR ........................................... 7-30 7-28 LOAD BACKREST - OPTION ................... 7-39
7-29 CASTER .................................................... 7-40

LIST OF TABLES

Table Page Table Page

3-1 DAILY CHECKS.............................................3-1 6-1 CONTROLLER SPECIFICATIONS
3-2 MONTHLY AND QUARTERLY INSPECTION PRIOR TO SERIAL NUMBER 373234 ..........6-7
AND SERVICE CHART .................................3-2 6-2 CONTROLLER SPECIFICATIONS
3-3 CHARGE TIME FOR BATTERY CHARGING3-3 SERIAL NUMBER 373234 TO 376836..........6-7
3-4 RECOMMENDED LUBRICANTS ..................3-3 6-3 FAULT RECOVERY EXCEPTIONS. .............6-9
3-4 LUBRICATION CHART..................................3-4 6-4 LED CODES ................................................6-13
6-5 TROUBLESHOOTING CHART....................6-14
6-6 ADJUSTMENT SETTINGS ..........................6-16

PTW1104 iii
 NOTES

iv PTW1104
 SECTION 1
DESCRIPTION

1-1. INTRODUCTION. The reversible DC motor propels the lift truck in for-
ward or reverse direction throughout the available
This publication describes the PTW 40 lift truck manu-
speed range. The PTW lift truck can be driven with
factured by Big Joe Manufacturing Company, Des
forks raised or lowered. The lift truck must be operated
Plaines, Illinois 60018. Resistor and transistor lift
and stored in an area where it will be protected from
trucks are covered in this manual, in 24 volt configura-
the elements.
tion. Included are operating instructions, planned
maintenance instructions, lubrication procedures, cor-
1-3. NAMEPLATE.
rective maintenance procedures and a complete parts
list with parts location illustrations. The nameplate is the key for identifying many of the
features of your lift truck. It provides information such
By following the recommendations contained in this
as:
manual, you will receive many years of dependable
service from your Big Joe lift truck. Model number
Serial number
1-2. GENERAL DESCRIPTION.
Maximum capacity, load center, and maximum lift
The self-propelled PTW 40 truck, Figure 1-1, lifts and
height
transports payloads up to 4000 pounds on rigid forks.
If applicable, alternate capacity, load center, and
The forward and reverse motion is controlled by either
maximum lift height
of two control levers mounted on the control head.
Stopping and turning is controlled by the steering arm. Truck weight without battery
Lift and Lower is controlled by pushbuttons located on Minimum weight of battery
the control head. The battery-powered lift truck is quiet
and without exhaust fumes. Battery voltage
Refer to Figure 1-1 for serial number locations, if the
nameplate becomes lost or illegible.

R5140

Figure 1-1. PTW-40 Lift Truck

PTW1104 1-1
1-4. SAFETY FEATURES. Flow control valve regulates maximum lowering speed
within prescribed limits.
The PTW is designed and engineered to provide max-
imum safety for operator and payload. Some of the Relief valve maintains hydraulic pressure within pre-
safety features incorporated into the design are: scribed limits.
Deadman brake to apply mechanical brake and cut off High visibility color scheme of truck provides visual
drive power when the steering arm is released. alert of trucks presence.
Belly-button switch to reverse truck should the opera-
1-5. OPTIONS.
tor accidentally pin himself against a wall or obstruc-
tion when backing in slow speed. Big Joe offers many options and accessories for the
PTW lift truck such as:
All control functions automatically return to "OFF"
when released. Keyswitch
Externally accessible quick-disconnect battery plug Cold Conditioning
within operator's reach.
Battery Discharge Indicator
Separately fused control circuits and power circuits.
Hourmeter For Motors
Lift carriage backrest to help stabilize the load. Load Backrest Extension
Readily accessible HORN button.
Transistor Drive (speed) Control
Slip-resistant hand grips to provide a firm hand hold for
operator.

1-2 PTW1104
 SECTION 2
OPERATION

2-1. GENERAL. 10. Do not handle loads which are higher than the
load backrest unless load is secured so that no
This section gives detailed instructions for the PTW 40
part of it could fall backward.
lift truck. Information is applicable to resistor and tran-
sistor trucks, in 24 volt configurations. The instructions 11. When leaving truck, neutralize travel control. Fully
are divided into the various phases of operations, such lower lifting mechanism and set brake. When
as operating lift, driving, and stopping. Routine pre- leaving truck unattended, disconnect battery.
cautions are included for safe operation.
2-3. GENERAL CONTROL OPERATION.
2-2. OPERATING PRECAUTIONS. The speed control (See Figure 2-1) located on each
WARNING: Improper operation of the lift truck may side of the control head provides fingertip control for
result in operator injury, or load and/or lift driving the truck. As the lower portion of the speed
truck damage. Observe the following control is pressed, it closes contacts for first speed in
precautions when operating the PTW lift the forward direction. Pressing the speed control far-
truck. ther closes a contact for second speed and farther,
third speed. The upper portion of the speed control
1. Do not operate this truck unless you have been governs the reverse speeds in the same manner.
trained and authorized to do so and have read all Pushbutton switches, located behind the belly button
warnings and instructions in this manual and on switch guard, activate the lift-lower controls and the
the truck. horn.
2. Do not operate this truck until you have checked Lowering the steering arm to the horizontal or raising
its condition. Give special attention to Tires, Horn, to the vertical applies the brake. (See Figure 2-2) All
Battery, Controller, Lift System, Brakes, Steering traction control power is shut off when the brake is
Mechanism, Guards and Safety Devices. engaged. When the steering arm is in the upright posi-
3. Operate truck only from designated operation tion, the brake acts as a parking brake. Deadman
position. Wear foot protection. Do not carry pas- braking occurs when the handle is released and spring
sengers. action raises it to the upright position.
4. Observe applicable traffic regulations. Yield right
2-4. DRIVING AND STOPPING PROCEDURES.
of way to pedestrians. Slow down and sound horn
at cross aisles and wherever vision is obstructed. 1. Grasp the grips of the steering arm so that the
speed control can be comfortably operated by
5. Start, stop, travel, steer and brake smoothly. Slow
either thumb. If equipped, turn on the key switch.
down for turns and on uneven or slippery surfaces
that could cause truck to slide or overturn. Use 2. Lower the steering arm to a comfortable position
special care when traveling without load as the above horizontal to disengage the brake and to
risk of overturn may be greater. energize the electrical circuits.
6. Always look in direction of travel. Keep a clear 3. To move forward (with load trailing), slowly press
view, and when load interferes with visibility, travel the lower portion of the speed control. Press the
with load or lifting mechanism trailing. forward speed control farther to increase speed.
Third speed may be cut out by use of the high
7. Use special care when operating on ramps-travel
speed cut out switch (optional on transistor lift
slowly, and do not angle or turn. Travel with lifting
trucks).
mechanism or load downhill.
4. To stop, release the speed control and lower the
8. Do not overload truck. Check capacity plate for
steering arm to the horizontal position. In this
load weight and load center information.
position, the brake pads apply pressure to the
9. Before lifting, be sure load is centered, forks are brake disc. Lowering the steering arm farther,
completely under load, and load is as far back as increases the braking force. The brake may also
possible against load backrest. be applied by raising the steering arm to the
upright position.

PTW1104 2-1
 R5095

Figure 2-1. Steering Arm Controls

R3629

Figure 2-2. Brake

2-2 PTW1104
NOTE: Procedures for movement in reverse are the To lift forks, push in LIFT button and hold until forks
same as in the forward direction. reach desired height. To lower forks, push in LOWER
button and hold until forks descend to desired height.
5. To travel in reverse, lower steering arm to a com-
fortable position above horizontal and slowly 2-8. LOADING AND UNLOADING.
press upper portion of speed control.
1. Move truck to location where load is to be picked
2-5. BELLY-BUTTON SWITCH. (Figure 2-1) up.

The belly-button switch minimizes the possibility of the 2. Move truck into position so forks are within pallet
driver being pinned by the steering arm while driving or skid, and the load is centered over the forks
the lift truck in slow speed, forward. If the guard and as far back as possible.
presses against the operator while the lift truck is 3. Raise forks to lift load.
being driven in forward, the guard actuates a switch 4. Drive to area where load is to be placed.
which changes the direction of the lift truck to reverse
direction in low speed. 5. Move truck to align load with its new position.
6. Lower the load until it rests squarely in place and
2-6. STEERING ARM RETURN SPRING. the forks are free.
The steering arm return spring automatically raises 7. Slowly move the truck straight backward, using
the steering arm to the upright position when the the FORWARD speed control, to remove forks
steering arm is released. If the steering arm snaps up from pallet.
abruptly, or does not return fully, the steering arm
return spring requires adjustment. Return truck to 2-9. PARKING.
maintenance for adjustment. When finished with moving loads, drive truck to its
maintenance or storage area. If equipped, turn off the
2-7. LIFT AND LOWER CONTROLS. key switch. Disconnect batteries from TO DRIVE
Lift/Lower Control buttons are located on the steering receptacle and connect to the TO CHARGE recepta-
control head, behind the belly button switch guard. cle. Charge batteries as necessary. Refer to battery
(Figure 2-1) care instructions, paragraph 3-4.

PTW1104 2-3
 NOTES

2-4 PTW1104
 SECTION 3
MAINTENANCE

3-1. GENERAL. operator on a daily basis to ensure the safety of the

equipment. Optional items are noted as such.
Maintenance includes both the operator daily check
procedures and scheduled maintenance which must WARNING: If the truck is found to be in need of
be performed by a qualified service technician. Any repair, unsafe, or contributes to an
needed service found during the operator daily check unsafe condition, report it immediately. If
or the monthly and quarterly scheduled maintenance during operation, the truck becomes
procedures must be performed by a qualified mainte- unsafe, report it immediately. Do not
nance technician. operate the truck until it has been
restored to safe operating condition. Do
3-2. OPERATOR DAILY CHECKS. not make any unauthorized repairs or
Table 3-1 is a check list identifying both visual and adjustments.
operational checks which must be performed by the

Table 3-1. Daily Checks

VISUAL CHECKS VISUAL CHECKS
ITEM PROCEDURE ITEM PROCEDURE
DAMAGE Check for bent, dented or bro- STEERING Check for binding or excessive
ken parts. play. Excessive play will be
indicated by shifting of the
LEAKS Check drive unit and hydraulic
transmission. If excessive
system.
play exists, check pivot bush-
TIRES AND Check drive wheel and load ings for wear (Paragraph 4-5).
WHEELS wheels for wear, damage,
TRAVEL Check all speed ranges, for-
binding, etc.
ward and reverse. No unusual
FORKS Check for bends and misalign- noise should be present.
ment.
HYDRAULIC Check lift and lower for binding
CABLES AND Check that they are in place CONTROLS or unusual noises, etc.
HOSES and not damaged.
BRAKES Check that brake stops truck
BATTERY Check water level, and vent within a safe distance and
caps for damage or plugging. works smoothly. Check dead-
BATTERY Check for cracks, burns and for man brake by releasing han-
CONNECTOR tight connections with truck dle.
receptacle. HOURMETER If equipped, check for proper
operation.
GUARDS Check load backrest, covers
and guards for damage. PARKING Holds truck in place.
BRAKE
SAFETY Check for damaged paint,
DEVICES cracks, or other damage. BATTERY Check that battery discharge
CHARGE indicator (if equipped) is on
FRAME AND Check for bent, dented or bro-
“full” or specific gravity of bat-
SERVICE ken parts
tery indicates full charge.
COVER
BELLY BUTTON Check for proper operation.
HORN Check for sounds.
SWITCH

PTW1104 3-1
 Table 3-2. Monthly and Quarterly Inspection and Service Chart
INTERVAL INSPECTION OR SERVICE
Monthly 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.

3-3. MONTHLY AND QUARTERLY CHECKS. 3-4.1. General.

Table 3-2 is a monthly and quarterly inspection and The life of the batteries can be extended by giving
service chart based on normal usage of equipment them proper care. Perform a daily check of the batter-
eight hours per day, five days per week. If the lift truck, ies whether or not the equipment is in daily use. DO
is used in excess of forty hours per week, the fre- NOT overcharge the batteries or battery life will be
quency of inspection and service should be increased shortened. DO NOT allow batteries to become com-
accordingly. pletely discharged (specific gravity 1.150 or less). This
will also greatly shorten battery life.
3-4. BATTERY CARE.
3-4.2. Battery Removal.
WARNING: Hydrogen gas from the batteries can
Removal of batteries requires that it be lifted up out of
explode. Do not smoke, use an open
it's compartment. (Paragraph 4-7.).
flame, or create an arc or sparks in the
vicinity of the batteries. Ventilate well 3-4.3. Testing and Charging Battery.
when in an enclosed space and when
charging. The batteries contain SULFU- Use the following procedure:
RIC ACID which causes severe burns. 1. Obtain a battery hydrometer.
Do not get in eyes, on the skin or cloth-
2. Use the hydrometer to check specific gravity of
ing. In case of contact, flush immediately
each cell.
and thoroughly with clean water. Obtain
medical attention when eyes are
affected.

3-2 PTW1104
NOTE: Battery specific gravity readings should agree 3-5. LUBRICATION.
within +0.025 from cell to cell. If variation is
Refer to Table 3-3 for recommended types of grease
greater, the battery may have to be replaced.
and oil. Table 3-4 in conjunction with Figure 3-1 identi-
CAUTION: Be sure that no cell plates are exposed fies the items requiring periodic lubrication.
(not covered by fluid) before charging. Table 3-4. Recommended Lubricants
Add distilled water sufficient to just cover (See Table 3-4 for Application)
top of cell plates. DO NOT over fill cells.
No. 1 Transmission oil—EP SAE 80W-90.
CAUTION: Use distilled water. Impurities in tap Capacity - 1.5 quart. Big Joe No. 055780
water will damage battery plates. (Replace with 055790, 1W-30, if cold con-
ditioning option for continuous operation
3. Charge batteries in accordance with Table 3-3. below 32°F is installed).
WARNING: Do not service batteries while on charge.
Do not connect or disconnect battery No. 2 Grease—Lithium base, general purpose.
from charger while charger is on. Big Joe No. 055750 (Replace with
055753 if cold conditioning option for
NOTE: A fully charged battery has a specific gravity continuous operation below 32°F is
of 1.260 to 1.275. installed).

4. After charging, check water level in each cell

No. 3 Hydraulic oil. Big Joe No. 900855 (Gallon)
again. Water level must cover plates but not be
or 900893 (Quart). (Replace with 055784
higher than the base of the battery cell filler neck.
if cold conditioning option for continuous
Table 3-3. Charge Time for Battery Charging operation below 32°F is installed).
No. 4 Engine lubricating oil - No. 20
SPECIFIC CHARGE TIME (Hours)
GRAVITY 15 AMP CHARGER 15 AMP CHARGER
155 AH BATTERIES 200 AH BATTERIES
1.250 2 2
1.240 3 4
1.220 4 5
1.200 7 8
1.180 8 10
1.160 10 12
1.140 12 14

PTW1104 3-3
 Table 3-4. Lubrication Chart

Time Fig 3-1 Location Method of Type Application Of Lubricant

Interval Index No. Application (Table 3-4)
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- 2 Steering Arm Can No. 4 1 or 2 drops each time serviced.
Annually Elbow
Annually 3 Transmission Can No. 1 Fill to plug level.
Housing
Semi- 4 Hydraulic Can No. 3 Lower carriage, fill to 1 inch below elbow
Annually Reservoir tap in reservoir.
40 Hours 5 Lift Linkage Sleeve Can No. 4 1 or 2 drops each time serviced. (20 bush-
Bushings ings)
Semi- 6 Pivot Tube Can No. 4 1 or 2 drops each time serviced.
Annually Bushings

R5141

Figure 3-1. Lubrication Diagram

3-4 PTW1104
 SECTION 4
ADJUSTMENT AND REPAIR

4-1. GENERAL.
This section contains information and procedures for NOTE: While removing the belly-button casting, the
maintenance of the PTW lift trucks. Maintenance two return springs will drop free. Catch the
includes adjustment, and repair. springs while pulling the casting away to pre-
This section contains illustrations identifying mainte- vent their loss. Resistor lift trucks have one
nance parts. The callouts on each illustration corre- belly-button switch, transistor trucks have a
spond to the reference index numbers in the stack of three.
applicable text.
3. Bend actuator levers of belly-button switch(es) to
Parts listings are provided in SECTION 7 of this man- adjust gap between rollers and belly-button cast-
ual. The part list provides the Big Joe Manufacturing ing as required (See Figure 4-1).
Company part number, the part description, and the
quantity of the part required in the assembly. CAUTION: If too small a gap exists between belly-
button switch actuator rollers and the
When identifying each part to be ordered, visually belly-button casting, the belly-button
compare the part in the illustration with the actual part switch(es) may be actuated constantly.
needed. To assure proper identification of each part
being ordered, include your truck model number, your 4. Reinstall belly-button casting, making certain all
truck serial number (see nameplate), the part number parts are back in place.
description, and quantity of the part(s) needed. If the 5. Check operation of the belly-button safety
nameplate becomes lost or illegible, refer to Figure 1-1 switch(es) by pressing the belly-button casting
for other serial number locations. while listening for the "click" that indicates that the
switch(es) have actuated.
4-2. PART NUMBER IDENTIFICATION.
NOTE: The click should be heard when the belly-but-
To determine the part number of a replacement part,
ton casting has moved about 50 percent of its
identify the assembly in which the part is used and
normal travel distance. If the click is heard at
locate the illustration (in SECTION 7) of the applicable
the beginning of travel, the switch(es) may
assembly. Find the index number for the part on the
actuate at inappropriate times. If the click is
illustration and refer to that index number in the parts
heard near the end of travel, they could be
list. If the part number is NP, order the next higher
unreliable and may not switch in some
assembly. If the part number is VAR, order by part
instances.
name with truck model number and serial number.
If the part is listed with more than one part number, 6. Repeat steps 2. through 5. until pressing the
select the proper part number by comparing the belly-button casting actuates the switch(es) prop-
description in the parts list with the specifications of erly.
your truck. Refer to the nameplate to determine appli- 7. Reconnect the battery.
cation to your truck.
WARNING: Testing of belly-button safety switch(es)
4-3. STEERING ARM AND CONTROL HEAD. in operation should be limited to areas
clear of obstacles against which an oper-
4-3.1. Belly-Button Switch Adjustment. ator could be pinned. Use low speed in
If the actuator gap of the belly-button switch needs forward.
adjustment, proceed as follows (Figure 4-1):
4-3.2. Potentiometer Testing and Adjustment
1. Disconnect the battery. (Transistor Units Only).
2. Drive out the roll pins that secure the belly-button 1. Disconnect the battery
casting (Figure 4-1). Drive from the left to the
2. Remove screws (20 and 64, Figure 4-3) and
right.
access covers (40 and 66).

PTW1104 4-1
 R5097

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

3. Check gap between rollers on directional switches 8. Rotate cam (46) in both forward and reverse
(7) and surface of cam (46). If required, adjust directions, until it stops. Verify that bypass switch
position of bracket (50) to obtain a 0.03 - 0.06 inch (7) closes in each direction, just prior to the stop.
clearance. 9. Reassemble the control head.
4. Disconnect the pin and receptacle housings
located at contactor panel, connecting the control 4-3.3. Resistor Control Head Switch Replacement.
cable (3, Figure 4-19) and wire harness (39, Fig- 1. Disconnect the battery.
ure 4-20, 21, Figure 4-21 or 12, Figure 4-22). Set
an ohmmeter to the RX1K (1000) scale and con- NOTE: Access to belly-button switch (3, Figure 4-2)
nect across pin contacts of wires 4 and 11 at the is provided by removal of safety cover (42);
control cable (3, Figure 4-19) pin housing. access to other switches is provided by
removal of top cover (54), bottom cover (30),
5. Slowly press the control lever (52, Figure 4-3) in
and switch plate (55).
the forward direction until a click indicating for-
ward switch closure is heard. Ohmmeter should 2. Refer to paragraph 4-3.1. if necessary to gain
indicate 4550 ± 250 OHMS. access to a defective belly-button switch.
6. If incorrect reading is obtained, use access hole,
NOTE: Switch operation may be checked with a con-
in side of control head (Figure 4-1) to gain access
tinuity light containing a battery, or with an
to the potentiometer, (3, Figure 4-3). Insert a
ohmmeter.
screwdriver blade into the slot on the back side of
the potentiometer (Figure 4-1) and turn slightly. 3. Replace a defective belly-button switch (3) as fol-
Vary the amount and direction of screwdriver rota- lows:
tion until the specified value is achieved.
a. Remove locknuts (7) and screws (19) to
7. Repeat step 5 while pressing control lever in release belly-button switch (3) and insulator
reverse direction. Meter readings should be the (2).
same as for the forward direction (± 200 OHMS).
If meter readings are not the same, adjust position b. Tag and disconnect electrical wires from
of bracket (44, Figure 4-3) as necessary to obtain belly-button switch (3).
the same values. Adjust the potentiometer again if c. Connect electrical wires to new belly-button
necessary. switch (3), as noted during removal.

4-2 PTW1104
 R5098

Figure 4-2. Control Head Assembly - Resistor

PTW1104 4-3
 R5099

Figure 4-3. Control Head Assembly - Transistor

4-4 PTW1104
 d. Install insulator (2) and belly-button switch (3) m. Install bottom cover (30) and secure with
and secure with screws (19) and locknuts (7). screws (13).
e. Adjust belly-button switch (paragraph 4-3.1.). n. Connect the battery.
4. Replace a defective high speed cutout switch (44) 4-3.4. Transistor Control Head Switch Replace-
as follows: ment.
a. Disconnect the battery. 1. Disconnect the battery.
b. Remove screws (52) and top cover (54).
NOTE: Access to belly-button switches (5, Figure 4-
c. Remove screws (53) to release cutout switch 3) is provided by removal of safety cover (54);
(44). access to other switches is provided by
d. Tag and disconnect electrical wires from cut- removal of top cover (66), bottom cover (40),
out switch (44). and switch plate (67).

e. Connect electrical wires to new cutout switch 2. Refer to paragraph 4-3.1. if necessary to gain
(44), as noted during removal. access to a defective belly-button switch.
f. Install cutout switch (44) and secure with NOTE: Switch operation may be checked with a con-
screws (52). tinuity light containing a battery, or with an
g. Install top cover (54) and secure with screws ohmmeter.
(52).
3. Replace a defective belly-button switch (5) as fol-
h. Connect battery. lows:
5. Replace a defective pushbutton switch (43 or 45) a. Remove locknuts (13) and screws (26) to
as follows: release belly-button switches (5) and insula-
a. Disconnect the battery. tor (4).

b. Remove screws (52) and top cover (54). b. Tag and disconnect electrical wires from
belly-button switches (5).
c. Remove screws (13) and bottom cover (30).
c. Connect electrical wires to new belly-button
d. Remove screws (15 and 16) to release switch switches (5), as noted during removal.
plate (55).
d. Install insulator (4) and belly-button switches
e. Remove screws (51) to remove lift or lower (5) and secure with screws (26) and locknuts
switch (43). (13).
f. Remove nut and washer from back of horn e. Adjust belly-button switch (paragraph 4-3.1.).
switch (45) to remove from switch plate (55).
4. If your unit is equipped with the optional high
g. Tag and disconnect electrical wires from speed cutout switch (57), replace it as follows:
defective switch.
a. Disconnect the battery.
h. Connect wires to new switch, as noted during
removal. b. Remove screws (64) and top cover (66).

i. To install lift or lower switch (43), position on c. Remove screws (65) to release cutout switch
back of switch plate (55) and secure with (57).
screws (51). d. Tag and disconnect electrical wires from cut-
j. To install horn switch (45), position on front of out switch (57).
switch plate (55) and secure with it's washer e. Connect electrical wires to new cutout switch
and nut. (57), as noted during removal.
k. Install switch plate (55) and secure with f. Install cutout switch (57) and secure with
screws (15 and 16). screws (65).
l. Install top cover (54) and secure with screws g. Install top cover (66) and secure with screws
(52). (64).
h. Connect battery.

PTW1104 4-5
5. Replace a defective pushbutton switch (56 or 58) 4-3.5. Steering Arm.
as follows:
1. Steering Arm Return Spring Adjustment (Figure
a. Disconnect the battery. 4-4).
b. Remove screws (64) and top cover (66). The tension on the steering arm return spring
should allow the steering arm to return gently to
c. Remove screws (20) and bottom cover (40).
the upright position. Excessive tension on the
d. Remove screws (22 and 23) to release switch steering arm return spring will cause the steering
plate (67). arm to snap up and may cause damage to the
e. Remove screws (63) to remove lift or lower electrical cable, brake linkage or the spring itself.
switch (56). If the steering arm does not return fully, first check
for binding in the brake linkage or wiring harness
f. Remove nut and washer from back of horn before making any adjustments. If no binding is
switch (58) to remove from switch plate (67). found, then the problem is with the steering arm
g. Tag and disconnect electrical wires from return spring. Refer to Figure 4-4 and proceed as
defective switch. follows to adjust the steering arm return spring
tension.
h. Connect wires to new switch, as noted during
removal. CAUTION: The steering arm (17) will have a ten-
i. To install lift or lower switch (56), position on dency to fall when the tension on the
back of switch plate (67) and secure with return spring (10) is released.
screws (63).
a. Hold the steering arm (17) in upright position
j. To install horn switch (58), position on front of and make sure the arm cannot fall.
switch plate (67) and secure with it's washer
b. Insert a 5/16 inch Allen wrench through hole
and nut.
in bottom of steering arm (17) and loosen
k. Install switch plate (67) and secure with screw (15). The spring tube (11) will rotate
screws (22 and 23). counterclockwise when screw (15) is loos-
ened.
l. Install top cover (66) and secure with screws
(64). c. With a pair of vise-grip pliers, grip the flat sur-
faces of spring tube (11) and rotate clockwise
m. Install bottom cover (40) and secure with
180 degrees.
screws (20).
n. Connect the battery. NOTE: The flat surfaces are on the protruding end of
the spring tube (11), where the pins (12 and
6. Replace a defective potentiometer as follows:
13) are installed.
a. Disconnect the battery.
d. Hold spring tube (11) in rotated position and
b. Remove screws (16, Figure 4-4) to release tighten screw (15) to secure.
the control head from the steering arm (17).
e. Check the spring action by lowering the
c. Disconnect flanged connector of wire har- steering arm (17) and returning it to the
ness assembly (55, Figure 4-3), by unthread- upright position two or three times.
ing the mating connector, and remove the
control head. f. If necessary repeat steps a through e,
increasing or decreasing amount of rotation
d. Refer to Figure 4-3 for parts relationship, if of the spring tube (11) until steering arm (17)
replacing potentiometer. Tag and disconnect returns gently to full upright position.
electrical wires. Carefully note the position
and orientation of all components, to help 2. Replacement (Figure 4-4).
ensure proper reassembly. The steering arm return spring (10) is replaced
while the steering arm (17) is in the upright posi-
tion.
a. Disconnect battery.

4-6 PTW1104
 b. Remove control head (Paragraph 4-3.4., Loosen and remove screw (15) and spacer
above). (14).

CAUTION: The steering arm (17) has a tendency to f. Disconnect brake rod (19) from clamp (8).
fall downward when the tension on the
CAUTION: Unless properly supported, steering arm
return spring (10) is released.
(17) will drop out of pivot cap (4, Figure
c. Hold steering arm (17) and make sure the 4-9) when spring tube (11, Figure 4-4) is
arm cannot fall. removed.

d. With a piece of chalk or crayon, draw a g. Put a block under steering arm (17) at pivot
straight line from center of spring tube (11, cap (4, Figure 4-9).
Figure 4-4) outward onto pivot cap (4, Figure
h. With a pair of vise-grip pliers, grip the flat sur-
4-9), marking radial position of tube to facili-
faces of spring tube (11, Figure 4-4) and
tate re-installation.
slowly pull it free from the steering arm (17),
e. Insert a 5/16-inch Allen wrench through hole pivot cap (4, Figure 4-9) and tube clamp (8,
in bottom of steering arm (17, Figure 4-4). Figure 4-4).

R5100

Figure 4-4. Steering Arm

PTW1104 4-7
NOTE: The flat surfaces are on the protruding end of 6. Cut off connector (5) from end of cable.
the spring tube (11), where the pins (12 and 7. Pull loose end of cable up, and let it extend
13) are installed. Steering arm return spring through top of pivot tube (12).
(10) will remain inside the spring tube (11).
8. Remove screws (3, Figure 4-13), nuts (10), lock-
i. Remove steering arm return spring (10) from washers (4), flat washers (9), and motor compart-
spring tube (11). If spring is severely jammed ment (service) cover (1).
and will not come loose, use punch and drive 9. Disconnect connector (7, Figure 4-5).
the 1/4-inch diameter roll pin (13) into the
tube. Save pin for re-use. Remove the spring. 10. Refer to Figure 4-17 for resistor trucks, or Figure
Tap roll pin back into place. 4-19 for transistor trucks. Remove wire tires and
clamps (5), as required to free control cable (3).
j. Lubricate the ends and the outer surface of Note routing of cable, and position of wire ties and
the new steering arm return spring (10) with cable clamps, to ensure proper installation.
a lithium base general purpose grease.
11. Using a suitable pin removal tool, tag and remove
k. Insert spring (10) into spring tube (11) and dead-man switch cable leads from pin locations
press in, making sure that one spring loop 13 and 14 in connector (7, Figure 4-5).
eye fits over the 3/8-inch pin (12) at the
12. Using a suitable pin removal tool, remove wires
closed end of the spring tube.
from pin locations 1 through 12 in connector (7)
l. Slide spring tube (11) into pivot cap (4, Fig- on the new replacement control cable.
ure 4-9) and steering arm (17, Figure 4-4) 13. Tape the cut end of the old cable to the wires just
through tube clamp (8) and through loop of removed from connector (7) on the new cable.
electrical cable. Slowly rotate spring tube a
few degrees each way until the steering arm 14. Grease the new cable with a lithium base grease
return spring (10) snaps into place over or silicone spray.
spring pin (5). Refer to Figure 4-5 for internal 15. Draw new cable into pivot tube (12) by pulling old
view of steering arm with return spring cable out through opening in transmission hous-
installed. ing.
m. Connect brake rod (19, Figure 4-4) to clamp 16. Secure connector (5) end of new cable, to prevent
(8), securing with new cotter pin (7). Install it from falling in pivot tube (12).
spacer (14) and screw (15), but do not 17. Remove old cable from new cable and wipe off
tighten. Align radial position of spring tube excess grease.
(11) in accordance with line drawn in step e.
Tighten screw (15). 18. Insert wires 1 through 12 into pin locations 1
through 12, respectively, in connector (7).
n. Remove block from under steering arm.
19. Insert dead-man switch cable leads into pin loca-
o. Install control head. tions 13 and 14 in connector (7), as noted during
p. Refer to paragraph 4-3.5., step 1, above, and, removal.
if necessary, adjust the tension on steering 20. Route new control cable, as noted during
arm return spring. removal.
q. Reconnect battery. 21. Group all cables coming from drive motor, dead-
man switch and control cable, and clamp as
4-3.6. Electrical Control Cable Replacement. shown on Figure 4-17 or Figure 4-19.
1. Disconnect battery. 22. Secure cables to transmission housing and power
2. Remove 4 screws (11, Figure 4-5) that fasten con- section frame with clamps (5) and associated
trol head assembly to steering arm. hardware. Use wire ties to bundle cables and
wires as noted during removal.
3. Disconnect the exposed connector (5).
23. Connect connector (7, Figure 4-5).
4. Remove cable clamps (1 and 2) and loosen loop
of cable that is around the spring tube assembly 24. Using a suitable pin removal tool, remove wires
(3). from pin locations 1 through 12 in connector (5).
Tape the wire ends together.
5. Remove pivot cap (10).

4-8 PTW1104
25. Pull the connectorless end of cable (4) over pin 29. Work steering arm up and down a few times to
(14) and under spring tube assembly (3). assure that the electrical control cable is not bind-
26. Eliminate excess cable slack in pivot tube (12); ing.
then secure cable with cable clamp (1). 30. Pivot transmission through entire turning range,
27. Loop cable around spring tube assembly as illus- observing that all electrical cables and wire leads
trated (Figure 4-5) and push connector end of will flex properly and not become caught or
cable into steering arm. pinched at any time.
31. Reinstall wires 1 through 12 into pin locations 1
CAUTION: Improper cable loop adjustment will through 12, respectively in connector (5).
damage cable. If too tight, cable will tear
when steering arm is in up position. If too 32. Reinstall the control head assembly, engaging
loose, cable will buckle or be pinched connector (5) to end of speed control harness (3,
when steering arm is in down position. Figure 4-17 or Figure 4-19) and secure with
screws (7, Figure 4-5).
28. Pull the cable until it is wrapped firmly around the 33. Install pivot cap (10).
spring tube assembly (3). Slack off approximately
1/2 inch and secure the cable in this position with 34. Install motor compartment (service) cover (1, Fig-
cable clamp (2). ure 4-13) and secure with flat washers (9), lock-
washers (4), nuts (11), and screws (3).
35. Connect the battery.

R5101

Figure 4-5. Electrical Control Cable Replacement

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 park
position or lowered to within 15 degrees from its lowest
position (Figure 2-2). Proceed as follows:
1. Disconnect battery.
2. Jack up the truck so the drive wheel is off the
ground; then securely block the truck to prevent
slipping.
3. Remove screws (3, Figure 4-13), nuts (10), lock-
washers (4), flat washers (9), and motor compart-
ment (service) cover (1). R5142

4. Secure steering arm assembly (17, Figure 4-4) in Figure 4-6. Brake Adjustment
a position that is approximately 15 degrees down
d. Tighten nuts (4, Figure 4-7) so that dead-man
from its park position or 15 degrees up from its
switch (2) is activated, but switch plunger is
lowest position.
not fully depressed.
5. Loosen the hardware securing the dead-man
switch (2, Figure 4-7), to bracket (8, Figure 4-8). e. Remove blocking and lower truck.

6. Remove the cotter pin (1, Figure 4-6), then slide f. Install service cover (1, Figure 4-13), flat
the rod (2) into the brake lever (3) far enough to washers (9), lockwashers (4), nuts (10), and
pull the link pin (4) out of the lever (5). screws (3).
7. Turn the link pin (4) to make the adjustment. g. Connect battery connector.
8. Slide the link pin (4) back into the lever (5), but do 4-4.2. Replacement of Brake Pads.
not insert the cotter pin (1) at this time.
1. Disconnect the battery.
9. Turn the drive wheel by hand to check brake
adjustment. If there is noticeable drag, go to step 2. Block the wheels to prevent the truck from rolling.
12. 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 spin
the drive wheel to make sure there is no drag. If
there is any drag, carefully readjust only enough
to 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 return
to the upright position.
b. Check that brake lever (15, Figure 4-8) has R5143

activated dead-man switch (2, Figure 4-7), Figure 4-7. Dead-Man Switch
indicated by an audible click.
c. If required, adjust position of dead-man
switch (2) by loosening nuts (4) and sliding
switch forward or back in mounting bracket
(8, Figure 4-8) so that switch is activated,
when brake starts to engage.

4-10 PTW1104
 R5144

Figure 4-8. Brake and Linkage

3. Remove screws (3, Figure 4-13), nuts (10), lock- 7. Remove the two nuts (19) and lockwashers (31).
washers (4), flat washers (9), and motor compart- 8. Carefully pull the bolts (20) just enough to clear
ment (service) cover (1). the mounting blocks (11) while you hold together
4. Position the steering arm (17, Figure 4-4) to the the remaining parts of the disc brake caliper
left as far as possible, and secure the steering assembly (18), then remove the assembly.
arm down from its park position, so the mechani- 9. Remove the bolts (20), spacers (21), springs (22),
cal brake is disengaged. and brake pad (23).
5. Remove the cotter pin (2, Figure 4-8) from the link 10. Remove the retaining ring (24), washer (25),
pin (17). spring (26), bracket (28), lever (29), and washer
6. Slide the rod (16) with link pin (17) far enough into (30) from the brake pad (27).
the brake lever (15) to pull the link pin out of the
lever (29).

PTW1104 4-11
11. Discard the springs (22 and 26) and brake pads 1. Disconnect battery.
(23 and 27). Replace them with new parts. 2. Block load wheels.
12. Assemble the washer (30), lever (29), bracket 3. Remove service cover.
(28), spring (26), washer (25) and retaining ring
(24) to the brake pad (27). 4. Remove cap (3, Figure 4-9) from the pivot cap (4).

13. Assemble the brake pad (23), springs (22), and 5. Label and disconnect wires.
spacers (21) to the two bolts (20). 6. Disconnect brake rods by removing cotter pin.
14. Slip the assembled parts onto the bracket (28) 7. Remove steering assembly.
and hold them so the bolt holes are aligned. 8. Support the transmission assembly and remove
15. Insert the bolts (20) through the mounting blocks the two snap rings (1) and drive the pin (2) from
(11), so the threaded portion of the bolts passes the pivot cap (4).
completely through. 9. Lower the pivot tube weldment (7) and transmis-
16. Assemble the two lockwashers (31) and nuts (19) sion down and out of the truck.
to the bolts (20).
4-5.2. Transmission Initial Disassembly.
17. Slide the link pin (17) into the lever (29) and
secure the link pin with the cotter pin (2). 1. Disconnect the battery.
18. Remove the restrictions from the steering arm. 2. Securely block load wheels.
19. Refer to paragraph 4-4.1. above, and adjust 3. Remove service cover.
brake. 4. Remove magnetic drain plug (19, Figure 4-10)
20. Install the motor compartment cover. and drain transmission.
21. Connect the battery. 5. Turn steering arm to gain access to cover (43).
6. Remove fourteen screws (45) and lock washers
4-4.3. Replacement of Dead-Man Switch.
(46) and cover (43).
1. Disconnect the battery. 7. Remove and discard gasket (42).
2. Block the wheels to prevent the truck from rolling. 8. Remove thrust washer (29), gear (28) and key
3. Remove screws (3, Figure 4-13), nuts (11), lock- (51).
washers (4), flat washers (10), and motor com-
partment (service) cover (1). NOTE: When reassembling, be sure to replace the
gasket and reinstall the magnetic drain plug
4. Remove screws (3, Figure 4-7), nuts (4), and before refilling the transmission with transmis-
dead-man switch (2). sion oil. Transmission holds 1-1/2 quarts oil.
5. Loosen the strain relief (1).
4-5.3. Drive Axle Removal.
6. Separate switch housing. Tag and disconnect
leads of cable from top of dead-man switch (2). 1. Perform Steps 1 through 8 in initial transmission
disassembly.
7. Connect leads of cable to top of replacement
dead-man switch (2), as noted during removal. 2. Raise the rear of the truck using jacks or other
suitable means so that drive wheel is off floor.
8. Install replacement dead-man switch (2) on
bracket assembly (8, Figure 4-8) and secure with 3. Remove snap ring (41, Figure 4-10), gear (40),
screws (3, Figure 4-7) and nuts (4). and key (39), then pull out shaft (33) and wheel
(13). Washers (34 and 35) and seal (36) will fall
9. Tighten strain relief (1).
free.
10. Adjust the dead-man switch (Paragraph 4-4.1.
above). NOTE: During reassembly be sure all washers, spac-
ers, and the seal are reinstalled in proper
4-5. TRANSMISSION, DRIVE MOTOR, DRIVE sequence as shown in the illustration.
WHEEL, AND PIVOT TUBE ASSEMBLY.

4-5.1. Transmission and Pivot Tube Assembly

Removal.

4-12 PTW1104
 3. Make sure the four cables to the drive motor are
properly 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 lock
washers (3) that hold motor mounting plate (4).
5. Tap motor mounting plate loose and remove
mounting 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 that
dowel pins in motor mounting plate are
aligned with corresponding holes in transmis-
sion housing.

4-5.5. Drive Motor Servicing.

The drive motor exposed surfaces should be cleaned
at least once a month to assure proper cooling of
motor. Use an air hose to blow bust off of motor sur-
faces. If the truck does not run and the drive motor is
at fault, inspect brushes (4, Figure 4-11 or 6, Figure 4-
12) and commutator (on armature). Replace brushes if
they are worn. Clean commutator of rough spots with
fine sand paper and remove accumulations of loose
particles.
If the motor is to be disassembled, remove it from the
transmission as follows:
1. Disconnect the battery.
2. Make sure the four cables to the drive motor are
properly 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 by
dowel pins and must be tapped loose when
removing the plate from the transmission.
4. Tap the motor mounting plate loose and remove
the mounting plate with motor, brake caliper,
brake disc and gear attached to armature shaft.
R5310
NOTE: Testing information available in Big Joe Motor
Figure 4-9. Pivot Cap and Tube Installation
Maintenance Manual.
4-5.4. Drive Motor/Brake Assembly Removal. 5. When reinstalling motor on transmission, be sure
1. Perform the initial disassembly, steps 1 through 8. dowel pins are properly positioned so that arma-
ture will line up with bushing in transmission; then
2. Remove the cotter pin that fastens the brake rod
tap motor mounting plate in place and fasten with
to the brake caliper lever.
four screws.

PTW1104 4-13
 R5311

Figure 4-10. Transmission Assembly

4-14 PTW1104
 USED ON TRUCKS
SERIAL NUMBERS
PRIOR TO 371794

R5312

Figure 4-11. Drive Motor Assembly

USED ON TRUCKS
SERIAL NUMBERS
371794 TO 376836

R6109

Figure 4-12. Drive Motor Assembly

PTW1104 4-15
 R5313

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

4-16 PTW1104
4-6. BASE, FRAME, AND FORK SECTION. freeing the load wheel (6). Be careful not to lose
the spacers (8).
4-6.1. General.
NOTE: If load wheels are worn appreciably, it is rec-
The base and frame section of the truck includes the
ommended that both front wheels be
information plates, decals, fork section, and load
replaced to assure equal load distribution on
wheels.
the wheels.
Removal and replacement of covers is straight-forward
and does not require detailed information, See Figure 5. Check bearings (7) for damage; rotate by hand,
4-13. Make certain that all decals remain on the truck checking for smooth, non-binding rotation.
and are legible. If decals are damaged or missing they 6. If either bearing (7) or the load wheel (6) is dam-
must be replaced, See Figure 1-1. aged, the entire load wheel assembly must be
replaced.
4-6.2. Load Wheel Replacement.
7. Install the load wheels as follows. One load wheel
1. Raise the forks. is installed in each wheel housing (9).
2. Block the drive wheel to prevent the truck from a. Start the shaft (11) into the wheel housing
rolling. (9).
3. Jack the forks up high enough to lift the load b. While sliding the shaft (11) completely into
wheels off the floor and block securely under the the wheel housing (9), install one spacer (8),
tips of the forks. the load wheel (6) and another spacer (8), in
4. Drive the pin (5, Figure 4-14) from the shaft (11), that order, onto the shaft (11).
and pull the shaft out of the wheel housing (9),
c. Secure the shaft (11) by installing the pin (5).

R5314

Figure 4-14. Fork Section Assembly

PTW1104 4-17
8. Remove blocking and lower forks to the ground. (22) through pivot, washers and roller assem-
bly, securing with pin (23).
4-6.3. Frame Assembly: Fork Section and Lift
Linkage Repair and Replacement. k. If adjustable pull rods (14 and 16) were sepa-
rated, assembly as follows:
1. Lift Linkage repair and replacement:
(1) Install nut (18) and lockwasher (19) fully
a. Lift complete truck to height sufficient to per- onto front pull rod (14).
mit access to lift linkage under forks. Provide
(2) Thread turnbuckle (20) approximately
blocking under power section frame and at
1-3/4" onto rod (14).
tips of forks.
(3) Thread rear pull rod (16) approximately
b. Drive pin (23, Figure 4-14) from shaft (28)
1-3/4" into turnbuckle (20).
and pivot (24). Support the pivot (24) and
linkage. Remove shaft (28) and washers l. Position rod (16) with washers (13), as
(13). Remove springs (21) and lower the required, in pivot (24). Ensure that the spring
pivot (24) and linkage toward the floor. bracket on rod raps around the underside of
rod, and install shaft (22). Secure shaft with
c. Drive pin (3) from shaft (4) in fork. Support
pin (23).
the wheel housing assembly and linkage.
Remove shaft (4) and washers (13). Remove m. Position rod (14) with washers (13), as
wheel housing assembly and assembled link- required, in wheel housing (9). Install shaft
age from the fork section (1). (12) through wheel housing, washers and
front rod end, securing with pin (5).
d. Drive pin (5) from shaft (12) and wheel hous-
ing (9). remove shaft (12) and washers (12), n. Position wheel housing (9) and washers (13)
separating wheel housing (9) from rod (14). as needed in fork section. Install shaft (4) and
secure shaft with pin (3).
e. If necessary for repair or replacement of
wheel housing (9) remove load wheels (Para- o. Position pivot (24) to align pivot bore with
graph 4-6.2.). bore in rear of fork and add washers (13) as
needed. Install shaft (28) and secure with pin
f. Drive pin (23) from shaft (22) and pivot (24).
(23). Attach springs (21) to each side of rod
Remove shaft (22) and washers (13), sepa-
(16) and underside of fork.
rating pivot from rod (16).
p. Adjust the pull rods as follows:
g. Drive pin (23) from shaft (22) and pivot (24).
Remove shaft (22), washers (13) and roller (1) Clamp the wheel housing (9) in place as
assembly (26) from pivot (24). shown in Figure 4-15.
(2) Measure the 18.38" dimension as shown
NOTE: Do not separate adjustable pull rods (14 and
in Figure 4-15. If measurement is within
16), and turnbuckle (20) unless necessary for
tolerance, pull rod does not need adjust-
rod replacement.
ment.
h. If wheel housing (9), rod (14 or 16), or roller (3) If adjustment is required, loosen the jam
(26) must be replaced with a new part, omit nut and adjust the turnbuckle as required
step i, below, for that component. to provide the 18.38" dimension.
i. Inspect sleeve bushings (10, 15, 17 and 27) (4) Lock adjustment by tightening the jam
for excessive wear or other damage. Sleeve nut.
bushings must be replaced if wall thickness
(5) Remove the clamp.
of bushing is less than 1/16 inch. Press in
new bushings so they are flush with outside (6) Adjust other pull rod in same manner.
edges within 0.02 inch. After installation, q. If removed, install load wheels (Paragraph
ream, if required, to bring bushing ID to 0.622 4-6.2. above).
+0.002/-0.000 inches.
r. Repeat steps b thru q, to repair/replace lift
j. Position roller assembly (26) with washers linkage of other fork.
(13), as necessary, in pivot (24). Install shaft

4-18 PTW1104
 R5333

Figure 4-15. Pull Rod Adjustment Details

2. Fork Section and Power Section Frame Separa- away from the fork section and place on
tion: blocking.
a. Support entire truck on blocking, providing h. Remove the four rollers (29, Figure 4-14) and
separate blocks so that the fork section can thrust bearings (30), noting thickness of
be fully supported when power section is thrust bearings at each roller.
removed.
3. Fork Section Repair:
b. Disconnect battery.
a. Inspect rollers (29, Figure 4-14) for wear, or
c. Remove batteries (Paragraph 4-7.). other damage. Replace defective roller if nec-
d. Remove cover (1, Figure 4-13). essary. Pack rollers with grease.
e. Ensure that hydraulic pressure has been b. Inspect sleeve bushings (25) for wear or
relieved from the lift circuit. Disconnect other damage. Bushing must be replaced if
hydraulic line from fitting at cylinder and wall thickness is less than 1/16 inch. Press
remove the fitting. new bushing into bore, flush with inside sur-
face of fork channel.
WARNING: Power section is heavy. Use care while
securing and lifting in order to prevent c. Inspect fork section (1) for broken welds and
injury. weld as necessary. Replace fork section if
forks have been bent severely.
f. With suitable hoist, carefully lower the power
section (11, Figure 4-13) slightly, so cylinder 4. Power Section Frame Repair:
rod end will clear socket in fork section. With a. Repair of power section frame (11, Figure 4-
access through battery compartment of 13) is limited to chasing damaged threads
power section, raise or lower power section in and welding of any broken welds.
order to align access holes in backrest with
b. Replace a worn or damaged U-clip nuts (2).
bolts holding the upper cylinder mount.
Remove bolts with extended socket, remove c. Removal of components mounted on power
mount. section frame may be necessary to effect
g. The power section may now be hoisted repairs/welding of frame, refer to table of con-
straight up sufficiently to allow the rollers on tents for identification of instructions on such
the fork section to clear the channels on the components.
power section. Move the power section on

PTW1104 4-19
5. Fork Section and Power Section Frame Assem- 1. Disconnect the battery plug (2, Figure 4-16) from
bly: the connector.
NOTE: Prior to assembly of the fork section and 2. Grab battery handle at exposed side of batteries,
power section, check adjustment of the fork lifting slightly to clear retainer rod and pull battery
pull rods, paragraph 4-6.3.. Frame Assembly: from side of power section frame.
Fork Section and Lift Linkage Repair and 3. Disconnect battery cables (2 and 6) from batter-
Replacement.C1.p. ies.
a. Install thrust bearings (30, Figure 4-14), as 4-7.2. Battery Cable Assemblies Replacement.
noted during removal, and rollers (29). If nec-
1. Disconnect batteries (paragraph 4-7.1.).
essary, adjust the number/thickness of thrust
bearings used to shim fork section rollers for 2. Remove screw (3, Figure 4-16) and lockwasher
proper fit into power section channels when a (4) to release battery cable assembly (2). Remove
new fork section is installed. clamp (5) from cable assembly.
b. Brush entire length of roller channels in frame 3. Remove screws and nuts that secure connector
(11, Figure 4-13) with grease (No. 2, Table 3- (handle) assembly (1) to connector on cable
4). assembly (2).
c. With hoist lift power section so that the chan- 4. Note routing of cables.
nels are slightly above rollers on fork section. 5. Pull cables (2) up out of battery compartment.
Move the power section into the fork section 6. Replace entire battery cable assembly (2 and 6) if
aligning rollers (29, Figure 4-14) with chan- cables are damaged. Use a multimeter to verify
nels of power section frame. Carefully lower continuity.
power section, engaging rollers in channels
7. Carefully route terminal end of cables (2) down
of power section frame.
into battery compartment.
d. Align access holes with bolt in top cylinder 8. Position clamp (5) on cable assembly (2), allowing
mount. sufficient cable length to plug cable connector to
e. With power section lowered sufficiently, posi- receptacles of battery charger and contactor
tion hydraulic cylinder in socket of frame and panel and secure with lock washer (4) and screw
support cylinder with item 4, 5, 6 & 7 (4, Fig- (3).
ure 4-29). 9. Connect battery cables (2 and 6) to batteries.
f. Raise power section sufficiently to engage 10. Connect battery plug (2) to TO DRIVE connector.
cylinder rod end in socket of fork frame.
4-7.3. Resistor/Contactor Panel (Figure 4-17 &
g. Install hydraulic fittings in cylinders and con-
Figure 4-18).
nect hydraulic lines.
1. Contactor Panel Removal.
h. Install cover (1, Figure 4-13).
a. Disconnect the battery.
i. Lower truck to floor, and install batteries
(Paragraph 4-7.). b. Remove screws (3, Figure 4-13), nuts (10),
lockwashers (4), flat washers (9), and motor
j. Connect battery.
compartment (service) cover (1).
4-7. ELECTRICAL. c. Refer to Figure 4-18 and tag and disconnect
all electrical wires and cables, which connect
4-7.1. Battery Removal and Replacement (Figure to the contactor panel.
4-16). d. Remove two nuts (7, Figure 4-17) and lock-
Batteries are pulled out and lifted from battery com- washers (6) to release and remove the con-
partment using the handles mounted on side of bat- tactor panel assembly and the speed control
tery case. resistor (11).
2. Contactor Panel Disassembly.
WARNING: Batteries available for the lift truck vary in
weight. A suitable hoist and sling a. Carefully tag and disconnect all electrical
arrangement must be used to prevent wires and cable assemblies, as shown on
injury or battery damage. Figure 4-18.

4-20 PTW1104
 R5315

Figure 4-16. Storage Batteries and Connectors

R5316

Figure 4-17. Electrical Installation - Resistor Trucks

PTW1104 4-21
 R5317

Figure 4-18. Contactor Panel Assembly - Resistor Trucks

4-22 PTW1104
 R5318

Figure 4-19. Electrical System Installation - Transistor Trucks

b. Refer to Figure 4-18 for location and identity c. Install motor compartment (service) cover (1,
of component mounted on the panel and Figure 4-13) and secure with flat washers (9),
remove defective part. lockwashers (4), nuts (10), and screws (3).
c. The forward and reverse contactors used on d. Connect the battery.
this panel are not repairable and must be
replaced if defective. 4-7.4. Transistor/Contactor Panel - Transistor
Trucks (Figure 4-19 thru Figure 4-22).
3. Contactor Panel Reassembly.
NOTE: Erratic operation of a transistor controlled
a. Install replacement parts in same location
truck, may be caused by defective controller
and orientation as removed defective part.
components. Before removing the contactor
b. Connect all electrical wires and cable assem- control panel, perform troubleshooting proce-
blies, as noted during removal and shown on dures per paragraph 6-3. to determine correc-
Figure 4-18. tive action to be taken.
4. Contactor Panel Installation.
1. Contactor Panel Removal.
a. Position the contactor panel with resistor, and
a. Disconnect the battery.
secure with lockwashers (6, Figure 4-17) and
nuts (7). b. Remove screws (3, Figure 4-13), nuts (10),
lockwashers (4), flat washers (9), and motor
b. Refer to Figure 4-18 and connect all electrical
compartment (service) cover (1).
wires and cables to the contactor panel, as
noted during removal. c. Refer to Figure 4-20 thru Figure 4-22 and tag
and disconnect all electrical wires and
cables, which connect to the contactor panel.

PTW1104 4-23
 USED ON TRUCKS
SERIAL NUMBERS
PRIOR TO 338607

R5319

Figure 4-20. Contactor Panel Assembly - Transistor Trucks

4-24 PTW1104
 USED ON TRUCKS
SERIAL NUMBERS
338608 TO 373233

R4133

Figure 4-21. Contactor Panel Assembly - Transistor Trucks

PTW1104 4-25
 USED ON TRUCKS
SERIAL NUMBERS
373234 TO 376836

R5319

Figure 4-22. Contactor Panel Assembly - Transistor Trucks

4-26 PTW1104
 d. Remove nuts (7, Figure 4-19) and lockwash- 7. Install motor compartment (service) cover (1, Fig-
ers (6) to release and remove the contactor ure 4-13) and secure with flat washers (9), lock-
panel assembly. washers (4), screws (3), and nuts (10).
2. Contactor Panel Disassembly. 8. Connect the battery.
a. Refer to Figure 4-20 thru Figure 4-22 for loca- 4-7.6. Battery Charger (Figure 4-24).
tion and identity of component mounted on
the panel and remove defective part. The battery charger is mounted in the upper right side
of the power section frame under the top cover. The
b. The forward and reverse contactors used on plug-in connector is accessible through an opening in
this panel are not repairable and must be the top cover, which also carries the charger ammeter.
replaced if defective. All replaceable parts are shown in Figure 4-24.
3. Contactor Panel Reassembly.
4-7.7. Wire Harness Testing.
a. Install replacement parts in same location
1. Wire harnesses are illustrated and identified on
and orientation as removed defective part.
the figures in this manual containing the compo-
b. Connect all electrical wires and cable assem- nents they are associated with. As an aid to test-
blies, as noted during removal and shown on ing, individual wires in each harness have their
Figure 4-20 thru Figure 4-22. wire numbers permanently marked on both ends.
4. Contactor Panel Installation. Refer to the wiring diagram (Figure 4-25 for Resis-
tor Units. Figure 4-26 thru Figure 4-28 for Transis-
a. Install contactor panel and secure with lock- tor Units).
washers (6, Figure 4-19) and nuts (7).
2. Testing procedures are as follows:
b. Refer to Figure 4-20 thru Figure 4-22 and
connect all electrical wires and cables to the a. Disconnect the battery.
contactor panel, as noted during removal. b. Tag and disconnect electrical wires as neces-
c. Install motor compartment (service) cover (1, sary.
Figure 4-13) and secure with flat washers (9), c. Disconnect plug(s) and/or receptacle(s), if
lockwashers (4), nuts (10), and screws (3). any.
d. Connect the battery. d. Using a multimeter, check all individual wire
leads for continuity. Continuity must exist in
4-7.5. Horn Replacement. each individual wire lead.
To replace the horn, proceed as follows: 3. If a wire harness fails continuity test, it must be
NOTE: The spike suppressor (4, Figure 4-23) is only replaced. Make careful note of harness routing,
applicable to transistor units. and location of any clamps or wire ties before
removing. Route new harness, and install any
1. Perform steps 2a and 2b, above. clamps or wire ties, as noted during removal.
2. Tag and disconnect all electrical connections from 4. Connect electrical wires, as noted during removal.
horn (5). 5. Connect any plug(s) and/or receptacle(s), as
3. Remove nuts (1), lockwashers (2), and flat wash- noted during removal.
ers (3) to release and remove the horn (5). 6. Connect the battery.
4. If working with a transistor unit, check the spike
suppressor assembly (4) for damage. If any part 4-7.8. Wiring.
is damaged, the entire spike suppressor assem- Electrical wiring installation for resistor trucks is shown
bly (4) must be replaced. on Figure 4-17 and Figure 4-18. Electrical wiring
5. Install horn (5) and secure with nuts (1), flat wash- installation for transistor trucks is shown on Figure 4-
ers (3), and lockwashers (2). 19 thru Figure 4-22. When removing or installing elec-
trical wires or cables, refer to the wiring diagrams (Fig-
6. Connect all electrical wires to the horn, as noted
ure 4-25 for resistor trucks, Figure 4-26 thru Figure 4-
during removal.
28 for transistor trucks), to help ensure proper installa-
tion.

PTW1104 4-27
 e. Refer to Figure 4-17 or Figure 4-19 and
remove clamps (5) from transmission and
underside of frame top-plate. Note position of
the different size hardware to help ensure
proper installation.
f. Remove wire ties as necessary to separate
cables. Disconnect control cable assembly
(3) at large connector, located at contactor
panel.
g. If removing the transmission, pull end of con-
trol cable up through opening on side of
transmission housing.

R5320

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 the
transmission.
1. Removal.
a. Refer to paragraph 4-3. for replacement of
control cable. Refer to paragraph 4-7.7.
above, for testing and replacement of wire
harness assemblies.
b. Disconnect battery.
c. Remove screws (3, Figure 4-13), nuts (10),
lockwashers (4), flat washers (9), and motor
compartment (service) cover (1).
d. Refer to Figure 4-17 for resistor trucks or Fig-
R5321
ure 4-19 thru Figure 4-22 for transistor trucks
and label all wire and cable leads connected
to motor and deadman switch, then discon- Figure 4-24. Battery Charger Installation
nect the leads.

4-28 PTW1104
 NOTES

PTW1104 4-29
 R5322

Figure 4-25. Wiring Diagram - Resistor Trucks

4-30 PTW1104
 USED ON TRUCKS SERIAL
NUMBERS PRIOR TO 338608

R5323

Figure 4-26. Wiring Diagram - Transistor Trucks

PTW1104 4-31
 USED ON TRUCKS SERIAL
NUMBERS 338608 TO 373233

R4131-1

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

4-32 PTW1104
 USED ON TRUCKS SERIAL
NUMBERS 338608 TO 373233

R4131-2

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

PTW1104 4-33
 USED ON TRUCKS SERIAL
NUMBERS 373234 TO 376836

R6126

Figure 4-28. Wiring Diagram - Transistor Trucks (Sheet 1 of 2)

4-34 PTW1104
 USED ON TRUCKS SERIAL
NUMBERS 373234 TO 376836

R6127

Figure 4-28. Wiring Diagram - Transistor Trucks (Sheet 2 of 2)

PTW1104 4-35
 R5324

Figure 4-29. Hydraulic System Installation

h. Inspect all electrical wires and cables for e. Check operation of dead-man switch and
damage. Using a multimeter, check suspect brake. Adjust as necessary (Paragraph 4-4.).
wires for continuity.
f. Install cover (1, Figure 4-13) and secure with
i. Tag and disconnect a damaged wire or cable flat washers (9), lockwashers (4), nuts (10),
and install replacement part in same location. and screws (3).
2. Installation. g. Operate truck to ensure electrical connec-
tions were properly made.
a. If removed, feed end of electric control cable
through opening in side of transmission on h. Connect the battery.
which bracket is mounted.
4-8. HYDRAULICS.
b. Connect all electrical wires and cables as
noted during removal and shown on Figure 4- 4-8.1. Line and Fitting Replacement.
17 or Figure 4-19.
c. Secure cables to transmission housing and WARNING: When forks are raised, pressure exists in
power section frame with clamps and associ- the hydraulic system lines and fittings. To
ated hardware. Use wire ties to bundle cables ensure release of pressure, forks must
and wires as noted during removal. be fully lowered and the battery discon-
nected before performing any mainte-
d. Pivot transmission through entire turning nance on the hydraulic system.
range, observing that electrical cables and
wire leads will flex properly and not become
caught or pinched at any time.

4-36 PTW1104
 R4356

Figure 4-30. Pump, Motor and Reservoir Assembly

NOTE: Leaking hydraulic fittings may be remedied by required, add hydraulic oil to bring to proper level.
simply tightening fitting. If this does not rem- Use hydraulic oil listed in Table 3-4.
edy the leak, the fitting or line must be 6. Reinstall the vent plug (15) and connect the bat-
replaced. tery.
1. Lower forks fully. 7. Operate the lift lower buttons to refill cylinder and
2. Remove battery (Paragraph 4-7.). lines with hydraulic oil.

3. Remove screws (3, Figure 4-13), nuts (10), lock- 8. Lower forks fully and disconnect battery.
washers (4), flat washers (9), and motor compart- 9. Remove the vent plug (15) and elbow (13) and
ment (service) cover (1). recheck level of hydraulic oil. Hydraulic oil must be
one inch below bottom of elbow (13). If required,
CAUTION: Hydraulic oil can damage parts. Wipe off add hydraulic oil to bring to proper level. Use
any oil immediately. Provide a container hydraulic oil listed in Table 3-4.
under line or fitting, before disconnect-
ing. 10. Reinstall vent plug.
11. Install motor compartment (service) cover (1, Fig-
4. Refer to Figure 4-29 and remove leaking line or ure 4-13) and secure with flat washers (9), lock-
fitting and replace it with a new line or fitting. washers (4), nuts (10), and screws (3).
5. Remove the vent plug (15, Figure 4-30), and 12. Install the battery (Paragraph 4-7.).
elbow (13). Check level of hydraulic oil. Hydraulic
oil must be one inch below bottom of elbow (13). If

PTW1104 4-37
 PACKING KIT
901498 CONTAINS:
ITEM QTY
1 1
2 1
4 1

R5325

Figure 4-31. Hydraulic System Installation

4-8.2. Hydraulic Pump, Motor, and Reservoir 3. Tag and disconnect all electrical wires from the
Assembly (Figure 4-30). pump, motor, and reservoir assembly (14, Figure
4-29).
The hydraulic pump, motor, and reservoir assembly
may be repaired. The motor and control valves can be 4. Remove hose assembly (8) and adapter (9).
repaired, however, a defective pump must be replaced 5. Remove screws (1), lockwashers (2), and flat
as a complete unit. Proceed as follows to remove and washers (3), to release and remove pump, motor,
disassemble the hydraulic pump, motor, and reservoir and reservoir assembly (14).
assembly.
6. Remove vent plug (15, Figure 4-30) and drain
WARNING: When forks are raised, pressure exists in hydraulic oil from reservoir into a clean bucket or
the hydraulic system lines and fittings. To suitable container.
ensure removal of pressure, forks must 7. Refer to Figure 4-29 for parts relationship and
be fully lowered and the battery discon- replace damaged components.
nected before performing any mainte-
nance on the hydraulic system. 4-8.3. Lift Cylinder Removal.

1. Lower forks fully and disconnect battery. Remove lift cylinder as instructed in paragraph 4-6.3.,
step 2.
2. Remove screws (3, Figure 4-13), nuts (10), lock-
washers (4), and flat washers (9) to release and
remove motor compartment (service) cover (1).

4-38 PTW1104
4-8.4. Lift Cylinder Repair. 4. Activate pump motor and observe reading on
pressure gauge. If pressure reading is between
To rebuild or replace components in a lift cylinder, pro-
2475 and 2575 psi, the relief valve is functioning
ceed as follows:
properly and does not need adjustment. If pres-
1. Secure the lift cylinder in a vise, clamping lightly sure reading is below 2475 psi or above 2575 psi,
at the base of the cylinder. proceed as follows to adjust relief valve:
2. With spanner wrench, remove the cylinder head
CAUTION: Do not set pressure too high or hydraulic
(3, Figure 4-31) from the cylinder weldment (6).
system may be damaged. Factory rec-
3. Withdraw the cylinder rod (5) from the cylinder. ommended limits of 2475 to 2575 psi
should be observed. Under no circum-
NOTE: If the, cylinder weldment (6), cylinder rod (5),
stances should pressure be set above
or cylinder head (3) is damaged, the entire lift
2575 psi.
cylinder must be replaced.
5. With pump motor running, observe pressure
4. Replace all wipers, seals and damaged or worn
gauge and set pressure between 2475 and 2575
parts.
psi by turning adjusting screw (14, Figure 4-30)
5. Coating all parts with hydraulic oil (Table 3-4). clockwise to increase pressure or counterclock-
6. Insert cylinder rod (5), with attached parts, into wise to decrease pressure.
cylinder weldment (6). 6. Deactivate pump motor, disconnect pressure
7. Install cylinder head and tighten to 5-7 lbs/ft. gauge, and reconnect hose.
7. Install motor compartment (service) cover (1, Fig-
4-8.5. Hydraulic Pressure Adjustment.
ure 4-13) and secure with flat washers (9), lock-
The relief valve is factory set to open at the rated pres- washers (4), nuts (10), and screws (3).
sure setting for the pump (not to exceed 2575 psi) and
rarely needs adjusting. If you suspect that the relief 4-9. DECALS AND TRIM.
valve is malfunctioning, perform the following proce-
dures: 4-9.1. Painting Requirements.

1. Lower forks as far as they will go. Clean all dirt, scale, and other foreign matter from sur-
faces to be painted. Touch up paint on frames and pull
2. Remove screws (3, Figure 4-13), nuts (10), lock-
rods with yellow enamel (901201). Touch up paint on
washers (4), flat washers (9), and motor compart-
remaining parts with black satin enamel (901202).
ment (service) cover (1).
3. Disconnect hose (8, Figure 4-29) from elbow at 4-9.2. Decals and Plates.
pump and connect a pressure gauge of adequate Refer to Figure 1-1 for location and identification of
range (0-3000 psi) to the elbow. decals and information plates. Make sure decals and
plates are legible and securely attached.

PTW1104 4-39
 NOTES

4-40 PTW1104
 SECTION 5
OPTIONS

5-1. BATTERY DISCHARGE INDICATOR. 5-2.1. Hourmeter Replacement.

Replacement parts for the optional battery discharge 1. Operation of the hourmeter (3, Figure 7-27) may
indicator are detailed in Figure 7-24. Refer to the wir- be checked against a watch.
ing diagram (Figure 4-25 for resistor trucks. Figure 4- 2. To replace the hourmeter (3), proceed as follows:
26 thru Figure 4-28 for transistor trucks.) to help
ensure proper connections. a. Disconnect the battery.
b. Remove screws (6, Figure 4-13), lockwash-
5-1.1. Battery Discharge Indicator Replacement.
ers (4), flat washers (7), and right hand cover
1. Operation of the battery discharge indicator (1, (8).
Figure 7-24) may be checked by comparing its c. Tag and disconnect terminals from hourmeter
reading against a hydrometer. Indicator should (3, Figure 7-27).
show a full charge when hydrometer shows a spe-
cific gravity of 1.260 to 1.275. d. Remove nuts (10), lockwashers (9), and
screws (2) to release and remove hourmeter
2. To replace the battery discharge indicator (1), pro-
(3), diode assembly (8), and insulating pad
ceed as follows:
(7).
a. Disconnect the battery.
e. Install hourmeter (3), insulating pad (7), and
b. Remove screws (6, Figure 4-13), lockwash- diode assembly (8), and secure with screws
ers (4), flat washers (7), and right hand cover (2), lockwashers (9), and nuts (10).
(8).
f. Connect terminals to hourmeter (3).
c. Tag and disconnect terminals (2, Figure 7-
g. Install right hand cover (8, Figure 4-13) and
24).
secure with flat washers (7), lockwashers (4),
d. Remove two knurled nuts and U-bracket, part and screws (6).
of battery discharge indicator (1), to release
h. Connect the battery.
and remove the indicator.

NOTE: Replacement indicator will be furnished with 5-3. KEYSWITCH.

nuts and U-bracket. The original U-bracket The optional keyswitch is shown in Figure 7-25. The
may be reused, if not damaged. keyswitch installation is accomplished by inserting the
supplied wiring into wire number 3, of control panel
e. Install battery discharge indicator (1) and
harness, at the slip-on connector of the in-line fuse.
secure with supplied U-bracket and nuts. If
Refer to the wiring diagram (Figure 4-25 for resistor
required, trim the U-bracket legs to proper
trucks. Figure 4-26 thru Figure 4-28 for transistor
length.
trucks) to help ensure proper connections.
f. Connect terminals (2), as noted during
removal. 5-4. COLD CONDITIONING PACKAGE.
g. Install right hand cover (8, Figure 4-13) and Continuous operation of the PTW lift trucks at temper-
secure with flat washers (7), lockwashers (4), atures below 32° F (freezing) in applications such as
and screws (6). meat lockers and freezers, requires the changing of
h. Connect the battery. oils and grease, and modification of the control head
and deadman switch as shown in Figure 7-26. For
5-2. HOURMETER. intermittent operation under 32° F, the oils and grease
need not be changed. Refer to the wiring diagram (Fig-
The hourmeter is available for attachment to the motor ure 4-25 for resistor trucks. Figure 4-26 thru Figure 4-
circuits to indicate use of the drive and lift functions. 28 for transistor trucks) to help ensure proper connec-
Refer to Figure 7-27 for replacement parts. Refer to tions.
the wiring diagram (Figure 4-25 for resistor trucks. Fig-
ure 4-26 thru Figure 4-28 for transistor trucks.) to help
ensure proper connections.

PTW1104 5-1
5-5. LOAD BACKREST. 5-6. CASTER
A load backrest is available for addition to the lift truck Casters are available for additional stability. Identifica-
to allow handling of high loads. Identification of tion of replacement parts are shown in Figure 7-29.
replacement parts, are shown in Figure 7-28.

5-2 PTW1104
 SECTION 6
TROUBLESHOOTING

6-1. TROUBLESHOOTING CHART.

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

Truck will not run, lift system a. 300 AMP fuse blown Check fuse (Figure 4-18 for Resistor Units.
does not operate. 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- Bypass keyswitch to determine if bad.
tive.
Truck does not run forward or a. Check all wiring. A loose con- Tighten all loose connections before fur-
reverse. All other functions nection may be the cause of ther troubleshooting
operate normally. malfunction.
b. Defective deadman brake Check and replace switch if defective.
switch.
c. Switch in control head broken. Check and replace switch if defective.
Truck runs forward but not in Defective switch in control head, Check for positive dc voltage at number 2-
reverse. or defective contactor. 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 Defective switch in control head, Check for positive dc voltage at number 1-
in forward. or defective contactor. 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 Defective speed control switch in Check for positive dc voltage at number 5-
reverse at lower speeds; will control head, or defective by-pass wire on by-pass contactor. If not present
not run at high speed. contactor. 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 a. Resistor Trucks: Defective or Check for clean, tight connection. Check
reverse at second or third open speed control resistor. for continuity and replace as required.
speed only. Truck does not
b. Transistor Trucks: Defective Replace transistor control.
move when control is in first
transistor control.
speed position. All else is nor-
mal.

PTW1104 6-1
 MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Mechanical brake grabs when Brake linkage overadjusted. Adjust brake.
steering arm is in operating
position.
Oil sprays or flows from top of Defective packing in lift cylinder. Overhaul lift cylinder and install new pack-
a lift cylinder. ing, seal, and wiper ring.
Squealing sounds when lifting a. Oil level too low. Add oil to reservoir.
forks.
b. Dry channels in mast. Apply grease.
c. Defective carriage bearing. Replace bearing.
Lift carriage does not lift to Oil level too low. Add oil to reservoir.
top.
Weak, slow or uneven action a. Defective pump or relief valve. Check pressure. Adjust valve.
of hydraulic system.
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 a. Battery is dead or discon- Check and recharge if required.
not run. nected.
b. Defective wiring. Check and repair as required.
c. Defect in electrical system for Check lift switch in control head, as well as
operating pump motor. 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 Disassemble, clean, and reassemble.
between check valve and Replace worn parts as required.
adapter body.
b. Worn lift cylinder packing. Replace cylinder packing.
Forks creep downward under Leak in hydraulic system cylinder Check lowering solenoid valve and internal
load when in a raised position. packing or lowering valve. 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 a. Return spring improperly Readjust spring tension.
to the upright position. adjusted.
b. Binding brake linkage or elec- Check and free the binding item.
trical cable.

6-2 PTW1104
 MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Truck moves forward when a. Belly-button switch defective. Check for short, and repair or replace as
arm is pulled down. necessary.
b. Short in control head. Check wiring and repair as required.
Steering arm jerks exces- a. Worn steering arm pivot bush- Replace bushings if difference between ID
sively starting or stopping the ings. of pivot bushings (5, Figure 4-9) and OD of
truck. 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.

6-2. CONTACTOR AND SWITCH TROUBLESHOOT- volts is present, the problem is in the contactor
ING. unit, and the contactor must be disassembled and
defective parts replaced.
If the truck does not run in one of the modes (Exam-
ple: truck runs in forward speed, but not in reverse), 6-2.2. Switch Testing.
the following tests can be performed to determine
whether the problem is in the switches or the contactor 1. Disconnect the battery.
unit itself. 2. Set the VOM test meter on the RX1 scale.

6-2.1. Contactor Testing. 3. Resistor Trucks: Connect the meter test probes
to the common #3 (#11 for pushbutton switches)
1. Make certain battery is in good condition and fully and the suspect switch lead* at the terminal con-
charged before beginning tests. nector.
2. Disconnect the battery and place strips of card-
board between the contactor tips to prevent cur- Transistor Trucks: Connect the meter test
rent from flowing during the test. probes to the common #3 (#10 for push button
3. Reconnect the battery. switches) and the suspect switch lead * at the ter-
minal connector.
4. Place the VOM test meter on the 50V scale and
connect the test probes to the (+) and (-) coil con- *NOTE: #2 switch lead for the reverse switch (transis-
nections of the suspect contactor (Figure 6-1). tor trucks) is shown in Figure 6-2.

NOTE: Testing of the reverse contactor is shown in 4. If the truck is equipped with a keyswitch, turn it on
Figure 6-1. and lower the control handle to the driving posi-
tion and depress the suspect switch.
5. If the truck is equipped with a keyswitch, turn it on
5. Resistance should read zero ohms, (or a small
and place the steering control in the run position
amount of ohms).
(brake off) and depress the speed control.
6. Voltage should read 24 volts, as applicable. If volt- 6. If resistance is present (10 ohms or more), the
age does not read 24 volts, the problem is in the switch or wiring leading to the connector is defec-
switches or wiring leading to the contactor unit. tive and must be repaired or replaced.
(See Paragraph 6-2.2. for switch testing.) If 24

PTW1104 6-3
 R5326

Figure 6-1. Contactor Testing

6-4 PTW1104
 R5327

Figure 6-2. Switch Testing

PTW1104 6-5
6-3. TRANSISTOR CONTROLLER TROUBLE- starts. (See adjustment instructions to adjust
SHOOTING. acceleration ramp setting.)
Refer to wiring diagrams included in SECTION 4 for 4. Current limiting
complete wiring diagram for this truck. Refer to these
diagrams and the schematic for tracing of electrical cir- The transistor controllers limit the motor current to
cuits during troubleshooting and testing procedures. a preset maximum. This feature protects the con-
troller from damage that might result if the current
6-3.1. Circuit Operation. were limited only by the motor demand. The cur-
While operation of the transistorized control system is rent limit feature also protects the rest of the sys-
transparent to the operator, it is helpful to understand tem. By eliminating high current surges during
the operating principles and features of the transistor vehicle acceleration, the stresses on the motor
controller when troubleshooting trucks equipped with and batteries are reduced and their efficiency and
this controller. The controller is mounted on the con- service life are improved. Similarly, there is less
tactor electrical panel, installed within the main hous- wear and tear on the vehicle drivetrain, as well as
ing of the lift truck. Figure 6-3 identifies the contacts of on the ground on which the vehicle rides (an
a typical controller. important consideration with golf courses and ten-
nis courts, for example).
1. Smooth stepless operation.
The maximum motor current can be factory-set to
The Big Joe custom transistor controller allows a lower value than the standard maximum if
superior operator control of the vehicle's drive requested. For further flexibility, the current limit
motor speed. The amount of current delivered to setting on some models is field-adjustable. (See
the motor is set by varying the "on" time (duty adjustment instructions.)
cycle) of the controller's MOSFET transistors.
This technique, called "pulse width modulation" 5. Plugging
(PWM), permits silent, stepless operation.
A form of electrical braking called plugging can be
2. Current multiplication used to slow the vehicle. When the motor is
reversed with the accelerator advanced (i.e.,
During acceleration and during reduced speed when the vehicle is moving), the armature acts as
operation, the controller allows more current to a generator. current from the armature flows
flow into the motor than flows out of the battery. through a plug diode in the controller. The control-
The controller acts like a dc transformer, taking in ler regulates the current in the motor field winding
low current and high voltage (the full battery volt- to give an appropriate level of plugging torque.
age) and putting out high current and low voltage. The vehicle slows smoothly to a stop, then auto-
The battery only has to supply a fraction of the matically accelerates in the other direction. A
current that would be required by a conventional 1 kHz tone may be heard during plugging. The
controller (in which the battery current and motor maximum plugging current is factory set per cus-
current are always equal). The current multiplica- tomer requirements, and is also field adjustable
tion feature gives vehicles using these controllers (see adjustment instructions).
dramatically greater driving range per battery
charge. 6. Undervoltage protection

3. Acceleration limiting The control circuitry requires a minimum battery

voltage to function properly. The controller is
A built-in acceleration limiting circuit maintains a therefore designed so its output is gradually
maximum rate of power increase to the motor. If reduced if the battery voltage falls below a certain
full throttle is applied at start-up, the acceleration level; the cutoff voltage for the various models is
ramp setting determines how quickly the output of listed in the specifications (See Table 6-1 and
the controller increases. The standard setting is Table 6-2). Reducing the output to the motor
such that with full throttle applied, the controller allows the battery voltage to recover, and an equi-
requires approximately one second to reach full librium is established in which the battery supplies
output. This feature contributes to smooth, gentle as much current as it can without falling below the
cutoff voltage.

6-6 PTW1104
 Table 6-1. Controller Specifications Table 6-2. Controller Specifications
Prior To Serial Number 373234 Serial Number 373234 to 376836
Big Joe Model 005467-01 005467-02 Big Joe Model 907200-02
Input Voltage 12 24-36 Input Voltage 24
Current Limit 400 Amps* 400 Amps* Current Limit 250 Amps*
Rating: Rating:
2 Minute 300 Amps 300 Amps 1 Minute 250 Amps
5 Minute 210 Amps 210 Amps 2 Minute 200 Amps
1 Hour 135 Amps 135 Amps 5 Minute 150 Amps
Voltage Drop @ 100 Amps 0.25 V 0.25 V 1 Hour 100 Amps

Under-voltage Cutback 9V 16 V Voltage Drop @ 100 Amps 0.25 V

Max F/R+1A Current 2 Amps 2 Amps Under-voltage Cutback 16 V

Operating Frequency 15 kHz 15 kHz Max F/R+1A Current 2 Amps

Standby Current mA mA Operating Frequency 15 kHz

Standard Throttle Input 0-5000 ohms, 0-5000 ohms, * 30 Second rating.

+10% +10%
* 30 Second rating.

Figure 6-3. Full Feature Electronic Motor Controller

PTW1104 6-7
7. Overvoltage protection 10. Controller fault protection (Prior to Serial
Number 373234)
Similarly, the controller has a means of preventing
operation when battery voltages are too high for Faults can be caused internally (e.g., shorted
proper functioning. Excess voltage can occur from transistors) or externally (e.g., wrench or hard-
an unregulated battery charger or from improper ware dropped across controller terminals). While
or faulty wiring. disabled, the controller's direction contactor out-
8. Thermal protection put and internal logic are both off.

Because they are well designed thermally, the Faults are detected by monitoring the controller's
controllers barely get warm in normal operation. M-output. If M-remains low for more than 20 ms, a
Overheating can occur, however, if the controller fault is detected. Fault protection is disabled for
is undersized for its application or otherwise over- throttle demand greater than 80%
loaded. If the internal temperature of the controller
exceeds 165°F, the current limit drops off steadily To recover from a fault, the F/R switch must be
until it is reduced to zero at 200°F. This allows the turned off and back on again. If the fault has been
vehicle to be operated at a reduced performance corrected, the controller will turn back on.
level in order to permit maneuvering out of the 11. Fault Detection (Serial Number 373234 To
way and stopping in a good place. After the con- 376836)
troller cools down, full current limit and perfor-
mance return automatically. Although this action An internal microcontroller automatically main-
is not damaging to the controller, it does suggest tains surveillance over the functioning of the con-
a mismatch. If thermal cutback occurs often in troller. When a fault is detected, the appropriate
normal vehicle operation, the controller is proba- fault code is signaled via the LED, externally visi-
bly undersized for the application, and a higher ble on the side of controller (See Figure 7-23 for
current model should be used. The controller LED location on controller). The diagnostic codes
shifts frequency during overtemperature from its flashed by the LED are listed in Table 6-4.
normal 15 kHz to 1 kHz, providing an audible tone
alerting the operator to the overtemperature con- If the fault is critical, the controller is disabled.
dition. More typically, the fault is a remediable condition -
for example, an undervoltage fault is cleared
The controller is also protected from undertem- when the condition is removed.
perature. Should its internal temperature fall
below -25°C (from being parked overnight in an The automatic fault detection system includes:
icehouse, for example), the current limit will be 1/3
contactor coil open / shorted driver (F/R and
the maximum. Once the controller warms above
shunt contractor)
-25°C, full current limit and performance return
automatically. contactor driver overcurrent / contactor coil
short
9. Accelerator fault protection (runaway
protection) contactor welded
emergency reverse circuit check
To prevent uncontrolled operation the controller
shuts off the motor output in the event of a short M- output fault
circuit fault in the accelerator or its wiring. The memory checks upon start-up
throttle configuration is a 2-wire potentiometer
overvoltage cutback
ranging from 5000 ohms for full off to 0 ohms for
full on. The controller returns to normal operation power supply out of range (internal)
when the fault (e.g., accelerator wiring, broken
throttle fault
connectors, potentiometers that fail or are set to
start at 0) has been corrected. undervoltage cutback
watchdog (external and internal)

6-8 PTW1104
 a. Hand Held Programmer. Table 6-3. Fault Recovery Exceptions.
FAULT RECOVERY
A hand held programmer is available that is anti-tiedown release and re-select Mode 1
designed specifically for use with the control-
contactor overcurrent when condition clears
ler. It serves dual functions of reading diag-
emergency reverse BB re-applied or brake cycled
nostic data provided by the controller and
HPD lower throttle to below HPD threshold
adjusting certain performance values of the
controller. The programmer (Part Number overvoltage when battery voltage drops below over-
voltage
005472-02) is available through your Big Joe
SRO when proper sequence is followed
dealer. If you require dealer location informa-
tion contact Big Joe Manufacturing Co. thermal cutback when temperature comes within range
phone number 847-298-9800. throttle fault clears when condition gone
undervoltage when battery voltage rises above under-
b. Fault Recording. voltage

Fault events are recorded in the controller's

memory. Multiple occurrences of the same 14. Arcless F/R and bypass contactor switching
fault are recorded as one occurrence.
Each time the F/R switch passes through neutral,
The fault event list can be loaded into the pro- the controller's output is rapidly turned off (even if
grammer for readout. The Special Diagnos- the throttle is held on) so that all motor current
tics mode provides access to the controller's has stopped by the time the direction contactor
diagnostic history file - the entire fault event drops out. Controller output always starts at zero
list created since the diagnostic history file and increases smoothly at the set acceleration
was last cleared. The Diagnostics mode, on rate each time a new direction is selected. Bypass
the other hand, provides information about contactor operation is also arcless, when inter-
only the currently active faults. rupting currents less than the controller's current
limit.
c. Fault Recovery (including recovery from
disable). 15. High pedal disable (HPD)

Almost all faults require a cycling of the KSI When the controller (KSI) is turned on, it will
or brake input to reset the controller and sense a “high” (advanced accelerator and will
enable operation. The only exceptions are inhibit the output until the accelerator is released
shown in Table 6-3. and reapplied. By preventing the unit KSI from
being turned on with the throttle depressed, this
12. Weather resistance
safety feature (also called Neutral Start) required
the truck to start smoothly from zero throttle when
All controllers are housed in rugged epoxy-
the battery is plugged in. It also protects against
sealed, anodized aluminum extrusions that pro-
sudden starts caused when problems in the throt-
vide excellent environmental protection.
tle linkage (e.g., bent parts, broken return sprint)
13. Emergency reverse: enhanced plugging give a partial or full throttle signal to the controller
current even with the accelerator released when the bat-
tery is plugged in.
Emergency reverse (or "belly button") switches
can be mounted on the handles of walkie vehi- 6-3.2. General Checkout (Serial Number 373234 To
cles. The emergency reverse switch is wired to 376836).
the controller and other vehicle electronics in such Carefully complete the following checkout procedure. If
a way that if the button is pressed against the you find a problem during the checkout, refer to Para-
operator by the advancing vehicle, the controller graph 6-3.4. for further information.
enables enhanced plugging current to stop the
vehicle quickly and revere its direction. The checkout can be conducted with or without the
handheld programmer (See Paragraph a.). The check-
out procedure is easier with a programmer. Otherwise,
observe LED for codes.

PTW1104 6-9
CAUTION: Put the vehicle up on blocks to get the Each input should show the correct state on the
drive wheel off the ground before begin- programmer.
ning these tests.
6. Check the controller's fault detection circuitry as
Turn the keyswitch off and make sure that described in paragraph 6-3.10.
the brake is applied (brake switch open),
7. Take the vehicle off the blocks and drive it in a
the throttle is in neutral, and the forward/
clear area. It should have smooth acceleration
reverse switches are open.
and good top speed.
Do not stand, or allow anyone else to 8. Test the plug braking of the vehicle. Verify that the
stand, directly in front of or behind the plug braking option is as desired (variable or
vehicle during the tests. fixed).
1. If a programmer is available, connect it to the pro- 9. Verify that all options, such as high pedal disable
grammer connector. (HPD), static return to off (SRO), and anti-
tiedown, are as desired.
2. Turn the keyswitch on. The programmer should
"power up" with an initial display, and the control- 10. Check to see whether the emergency reverse
ler's Status LED should begin steadily blinking a (belly button) feature is working correctly. Verify
single flash. If neither happens, check for continu- that the circuit is operational by momentarily dis-
ity in the keyswitch circuit and controller ground. connecting one of the emergency reverse wires.
The vehicle should be disabled and a fault indi-
3. If you are using a programmer, put it into the diag-
cated.
nostic mode by pressing the "DIAGNOSTICS"
key. The display should indicate "No Known 6-3.3. Troubleshooting (Prior To Serial Number
Faults." 373234).

Release the brake by pulling down the control arm The following procedures are to fix vehicles that don't
into the operating position. The LED should con- operate properly. Refer to wiring diagrams included in
tinue blinking a single flash and the programmer SECTION 4 when conducting these tests. Make sure
should continue to indicate no faults. If there is a the controller is hooked up as shown in Figure 6-3.
problem, the LED will flash a diagnostic code and Refer to the wiring diagram and schematic for your
the programmer will display a diagnostic mes- vehicle. These tests require a general purpose volt
sage. If you are conducting the checkout without a ohmmeter; you can use either a conventional "V-O-M"
programmer, look up the LED diagnostic code in or an inexpensive digital voltmeter.
Table 6-4. In general, when a problem has been isolated to the
controller, remove and replace it. If the source of the
When the problem has been corrected, it may be problem has not been determined or is suspected to
necessary to cycle the brake in order to clear the be within the truck (not the controller), proceed as
fault code. directed.

4. With the brake released, select a direction and NOTE: Working on electric vehicles poses some
operate the throttle. The motor should begin to dangers. You must protect yourself against
turn in the selected direction. If it does not, verify runaways, high current arcs, and outgassing
the wiring to the forward/reverse switches, for- from lead acid batteries:
ward/reverse contactors, and motor. The motor
should run proportionally faster with increasing Runaways - Some fault conditions could
throttle. If not, refer to Paragraph 6-3.4. cause the vehicle to run out of control. We
suggest that you jack up the vehicle and get
5. If you are using a programmer, put it into the test the drive wheels off the ground before
mode by pressing the "TEST" key. Scroll down to attempting these procedures or any other
observe the status of the forward, reverse, brake, work on the motor control circuitry.
emergency reverse, and mode switches. Cycle
each switch in turn, observing the programmer. High current arcs - electric vehicle batteries
can supply very high power for short times. if

6-10 PTW1104
 they are accidentally short circuited, arcs can troller's B- terminal and check the following
occur. Always open the battery circuit before points with the voltmeter (+) lead to trace the
doing work on the motor control circuit. Wear flow:
safety glasses and use properly insulated
(1) First, check both sides of the control wir-
wrenches to prevent accidental shorts.
ing fuse.
Lead acid batteries - Charging or discharg- (2) Check both sides of the keyswitch (if
ing batteries generates hydrogen gas, which truck is so equipped).
can build up in and around the batteries. (3) Check both sides of the accelerator
Always follow the battery manufacturer's rec- microswitch.
ommendations when working around batter-
(4) Finally, check the contactor coil and con-
ies. Wear safety glasses.
troller KSI.
1. Check for Power to the Controller e. If the contactor coil and KSI are getting volt-
a. Leave the keyswitch off for these tests (if age, make sure that the contactor is really
truck is so equipped). working, by connecting the voltmeter across
its big terminals. There should be no measur-
b. Verify that battery (-) connects to the B- ter- able voltage drop. If you see any at all, the
minal of the controller. connect voltmeter (-) contactor is bad.
lead to this point.
3. Check Potentiometer Circuitry
c. Connect voltmeter (+) to the battery side of
the power fuse. Check for full battery voltage. The following procedure applies to the basic
If it is not there, the trouble is in the battery accelerator input configuration for these control-
pack or the cables to it. lers, which is a nominal 5000 ohm potentiometer
connected as a two-wire rheostat (0 ohms = full
d. Connect the voltmeter (+) lead to the control- on, 5000 ohms = full off). Some controllers are
ler B+ terminal. You should read full battery sold with other input characteristics. If your instal-
voltage. If this voltage is zero or close to zero, lation used one of these optional inputs, find out
the trouble is either a bad controller, a bad what its range is and use a procedure comparable
power fuse, or an incorrectly connected to the one blow to make sure your accelerator is
cable. Trace the cable to make sure it is working correctly.
hooked up right. If these check out, the con-
troller is malfunctioning. a. With the forks lowered, the keyswitch off, and
the battery disconnected, pull off the connec-
2. Check for Contactor Operation and Keyswitch tors going to the accelerator inputs of the
Input (KSI) controller. connect an ohmmeter to the two
a. Turn the key on and move the accelerator in wires and measure the resistance as you
forward or reverse, until the microswitch oper- move the accelerator. The resistance at the
ates. limits should be within these ranges:
b. This should cause the main contactor to
Accelerator at Start: 4300 ohms to 4800
operate with an audible click. Connect the
ohms
voltmeter across the contactor coil terminal.
You should see full battery voltage.
Accelerator at Maximum: 0 ohms to 50 ohms
c. The controller KSI terminal (top push on)
b. If these resistances are wrong, it is because
should also be getting full battery voltage.
the potentiometer itself is faulty or out of
Verify this with the voltmeter. Connect the
adjustment, the wires to the pot are broken or
voltmeter (-) to the controller B- terminal, and
misconnected, the linkage is not moving the
the voltmeter (+) to the controller's KSI termi-
pot shaft through its proper travel or a switch,
nal.
resistor, or the relay is defective or incorrectly
d. If the contactor and KSI terminal are not get- wired. (See wiring diagram.)
ting voltage, that's the problem. Use the volt-
c. While you have the accelerator wires off the
meter to find out where it is not getting
controller, use an ohmmeter to check for
through. Connect the voltmeter (-) to the con-
shorts between these wires and the vehicle

PTW1104 6-11
 frame. You should see a resistance of at least are appropriate, release the accelerator, turn
10,000 ohms. If it is lower than that, inspect off the keyswitch, disconnect the battery, and
the wiring for damaged insulation or contact reconnect the wire to the direction contac-
with the frame. If necessary, replace the tors.
potentiometer.
d. The next step is to measure the current in the
d. Push the wires back on the controller termi- controller's M- lead. If you have a means of
nals. measuring this high dc current, such as a
e. Inspect the terminal area of the controller shut/meter setup or a clamp-on dc ammeter,
closely. Occasionally a build-up of dirt or acid use it. If not, we recommend that you buy an
residue of a conductive nature may cause ammeter of the type that is simply held
electrical leakage between the accelerator against the wire being tested. these are avail-
input terminals and the B- or M- terminals, able for a low cost at auto parts stores.
leading to faulty accelerator operation. To though the accuracy of these meters is not
check for this problem, measure the voltage great, they are adequate for this test.
at the upper pot terminal (by connecting the e. Connect the battery, turn the keyswitch on,
voltmeter (-) lead to the controller's B- termi- move the accelerator in either forward or
nal). The keyswitch must be on and a direc- revere, and watch the ammeter while advanc-
tional switch engaged for this test. ing the accelerator.
f. If you see no current flowing in the M- lead,
Lower Terminal
the problem is an open circuit in the motor or
the wiring between the motor and the control-
Accelerator at Start: 2.7 volts
ler. Check the F/R switch. If your vehicle uses
contactors for reversing, check to see that
Accelerator at Maximum: 7.0 volts
they are operating and that their contacts are
closing. If these are okay, check the motor
Compare your readings with these; if they are
armature and field for opens.
different by more than a few tenths of a volt,
contamination is probably the trouble. g. If you do see a high current flowing in the M-
lead, but the motor does not turn, the prob-
f. Carefully clean off the terminal area of the
lem is either a short in the motor circuit, a
controller with a cotton swab or clean rag
miswired motor, or a short in the controller's
moistened with water, and dry thoroughly.
internal plug diode. Test the plug diode as fol-
Now test the controller to see if proper opera-
lows:
tion is restored. If so, you should take steps
to prevent this from happening again. You (1) Remove power by opening the battery
must keep dirt and water from reaching the circuit. Take the cable off the controller's
terminal area of the controller. A2 terminal.
4. Check for controller output (2) Use an ohmmeter to check the resis-
tance between the controller's A2 and B+
a. Disconnect the wire from the direction con- terminals. You are testing for the pres-
tactors to the F/R contactor output of the con- ence of a diode inside the controller, so
troller. swap the two leads of the ohmmeter and
b. Connect the voltmeter (+) lead to the control- look for a low resistance one way and a
ler's B+ terminal. Connect the voltmeter (-) much higher one the other way. If your
lead to the controller's M- terminal. meter has a diode test function, use it.
c. Connect the battery, turn on the keyswitch, (3) If you find the diode to be shorted, the
move the accelerator in forward, and watch controller is bad and needs to be
the voltmeter as you advance the accelerator. replaced.
The voltmeter should read zero with the h. Put the A2 cable back on the controller.
accelerator released, and should read full
battery voltage with the accelerator at maxi- i. If the plug diode is OK, there is a short in the
mum. If it does not, the controller is bad and motor circuit. An ordinary ohmmeter will not
must be replaced. If the voltmeter readings work to find the short, because the resis-

6-12 PTW1104
 tances of the motor windings are so low. Test 1. LED Diagnostics
the motor separately if it is suspected of hav-
ing a shorted winding. During normal operation, with no faults present,
the Status LED flashes a single flash at approxi-
j. Verify all illustrated connections and compo-
mately 1 flash/second. If the controller detects a
nentry (Chapter 4) within the truck. If all
fault, a 2-digit fault identification code is flashed
check out and the source of the problem still
continuously until the fault is corrected. For exam-
has not been found, replace the controller.
ple, code "3,2" - welded direction contactor -
6-3.4. Diagnostics And Troubleshooting appears as:
(Serial Number 373234 To 376836). ooo oo ooo oo ooo oo
The controllers provide diagnostics information to (3,2) (3,2) (3,2)
assist in troubleshooting drive system problems. The The codes are listed in Table 6-4. For suggestions
diagnostics information can be obtained in two ways: about possible causes of the various faults, refer to
reading the appropriate display on the programmer or Table 5. Troubleshooting Chart.
observing the fault codes issued by the Status LED.
The Status LED is located on side of the controller Operational faults - such as overtemperature - are
(See Figure 7-23 for location of LED on controller). cleared 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 after
the problem is remedied.
Table 6-4. LED Codes

LED CODE EXPLANATION

LED Off no power or defective controller

Solid On defective controller

Single Flash o controller operational; no faults

1,2 o oo hardware fail-safe error
1,3 o ooo M- fault or motor output short
1,4 o oooo sequencing fault (SRO)
2,1 oo o 5kΩ-0 or throttle wiper input fault
2,2 oo oo emergency reverse circuit check fault (BB wiring)
2,3 oo ooo high-pedal-disable fault (HPD)
2,4 oo oooo throttle pot low open or shorted to B+ or B-
3,1 ooo o contactor or shunt driver overcurrent
3,2 ooo oo welded direction contactor
3,3 ooo ooo [reserved for future use]
3,4 ooo oooo missing contactor or shunt
4,1 oooo o low battery voltage
4,2 oooo oo overvoltage
4,3 oooo ooo thermal cutback
4,4 oooo oooo [reserved for future use]

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

PTW1104 6-13
2. Programmer Diagnostics The following 4-step process is generally used for
diagnosing and troubleshooting an inoperative vehicle:
With a programmer, diagnostics and troubleshoot- (1) visually inspect the vehicle for obvious problems;
ing is more direct than with the LED alone. The (2) diagnose the problem, using the programmer; (3)
programmer presents complete diagnostic infor- test the circuitry with the programmer; and (4) correct
mation in plain language - no code to decipher. the problem. Repeat the last three steps as necessary
Faults are displayed in the Diagnostic Menu, and until the vehicle is operational.
the status of the controller inputs/outputs is dis-
Refer to Table 6-5 for suggestions covering a wide
played in the Test Menu.
range of possible faults.
Table 6-5. Troubleshooting Chart

LED CODE PROGRAMMER EXPLANATION POSSIBLE CAUSE

LCD DISPLAY
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)

LED CODE PROGRAMMER EXPLANATION POSSIBLE CAUSE

LCD DISPLAY
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.

6-3.5. Adjustment of Controller Potentiometers

(Prior To Serial Number 373234).
The controller has adjustable plug current, current
limit, and acceleration rate settings. The locations of
the adjustment pots are shown in Figure 6-4.

NOTE: Stop the truck and release the handle during

adjustment.

1. Remove the socket head screw (1/8" Allen) for the

adjustment you want to make.
2. Adjust the internal potentiometer with a small
insulated screwdriver, in order to provided the
desired performance for the identified characteris-
tics.
3. Replace socket head screw and nylon seal R5133

washer. Tighten to 8 inch-pounds maximum to Figure 6-4. Location of Adjustment Pots

prevent stripping.
Some parameters have dependencies on other
6-3.6. Adjustment (Serial Number 373234 To parameters. When the programmer is being used to
376836). adjust a parameter and a limit is reached, the display
will stop changing. To see why the display has stopped
To change a parameter using the programmer, press
changing, press the "MORE INFO" key. If the limit is
the "PROGRAM" key, and scroll down the Program
related to another parameter, that information will be
Menu until the desired parameter is the top line of the
displayed; changing the value of the related parameter
display. Press the appropriate "CHANGE VALUE" key
may allow the original parameter to be adjusted fur-
("up" or "down") until the desired number is reached.
ther. Otherwise, the display simply says "Max Limit" or
The parameter is now set at the desired value. All pro-
"Min Limit".
gramming occurs in real time. That is, the parameter
can be changed while the vehicle is in operation.

PTW1104 6-15
 Table 6-6. Adjustment Settings To see the present status of the unit, use the Menu
Function Setting Navigation Key to select:
Creep Speed 7 Faults->System Faults.
Mode 1 Plugging Current Limit Not Used To access this log, use the Menu Navigation Key to
Mode 1 Acceleration Rate Not Used select:
Mode 2 Plugging Current Limit 80 Faults->Fault History.
Mode 2 Acceleration Rate 1.0
The faults are shown as a code and descriptive text. If
Mode 2 Maximum Speed 100
there are multiple faults, you have to scroll through the
6-3.7. Maintenance (Serial Number 373234 To list using the Up and Down Buttons on the Menu Navi-
376836) gation Key.

There are no user-serviceable parts inside the control- The faults may be intermittent faults, faults caused by
lers. No attempt should be made to open the control- loose wires, or faults caused by operator errors. Faults
ler. Opening the controller may damage it and will void such as contactor faults may be the result of loose
the warranty. wires; contactor wiring should be carefully checked
out. Faults such as HPD or overtemperature may be
The transistor controller is programmed at the factory caused by operator habits or by overloading.
specifically for the truck model on which it is equipped.
It is important to replace the controller with the correct After a problem has been diagnosed and corrected,
preprogrammed unit to assure proper performance clearing the diagnostic history file is advisable. This
settings intended for that particular truck. See Figure allows the controller to accumulate a new file of faults.
7-23 for the preprogrammed controller number. By checking the new diagnostic history file at a later
date, you can readily determine whether the problem
It is recommended that the controller exterior be was indeed completely fixed.
cleaned periodically, and if a handheld programmer is
available, this periodic cleaning provides a good To clear the diagnostic history file, select:
opportunity to check the controller's diagnostic history Faults->Clear Fault History.
file. It is also recommended that the controller's fault You will be asked to confirm your actions. Use the
detection circuitry be checked whenever the vehicle is increment arrow (+) for yes and decrement arrow (-) to
serviced. cancel and not clear the Fault History.
6-3.8. Cleaning (Serial Number 373234 To 376836) 6-3.10.Test the Fault Detection Circuitry (Serial
1. Remove power by disconnecting the battery. Number 373234 To 376836)
2. Discharge the capacitors in the controller by con- 1. Put the vehicle up on blocks to get the drive wheel
necting a load (such as a contactor coil or a horn) off the ground.
across the controller's B+ and B- terminals. 2. Disconnect the battery and make sure the key-
3. Remove any dirt or corrosion from the bus bar switch is off.
area. The controller should be wiped clean with a 3. Using an inline fuse holder fitted with a 10 amp
moist rag. Allow it to dry before reconnecting the fuse and alligator clips, connect the controller's M-
battery. and B- terminals.
4. Make sure the connections to the bus bars are 4. Turn the keyswitch on, release the brake and
tight. Use two well insulated wrenches for this apply the throttle. The motor should not operate,
task in order to avoid stressing the bus bars. and the direction contactors should not pull in.
6-3.9. Diagnostic History (Serial Number 373234 5. Leave the keyswitch on and remove the inline
To 376836) fuse wire. The vehicle status should continue to
remain off.
The handheld programmer can be used to access the
controller's diagnostic history file. When the program- 6. Cycle the keyswitch off and on, release the brake,
mer is connected to the unit, the error log file is auto- and apply the throttle. The vehicle should now
matically uploaded into the handheld programmer. operate normally.

6-16 PTW1104
 SECTION 7
ILLUSTRATED PARTS BREAKDOWN

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

PTW1104 7-1
 R5098

Figure 7-1 Control Head Assembly, Resistor

7-2 PTW1104
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505050-07 CONTROL HEAD 1 25 075510 . COMPRESSION SPRING 2
1 005647 . CONNECTOR 1 26 077007 . WASHER 4
2 018202 . SWITCH INSULATOR 1 27 077204 . SPLIT LOCK WASHER #6 4
3 020669 . MICRO SWITCH 1 28 402827 . SHAFT 1
4 020775 . MICRO SWITCH 4 29 402828 . CAP 2
5 052956 . FLANGED BEARING 2 30 402830 . BOTTOM ACCESS COVER 1
6 056617 . FORWARD-REVERSE DECAL 1 31 403358 . TUBE 2
7 059633 . HEX LOCK NUT, 2-56 2 32 402836 . SPACER 2
8 059634 . HEX LOCK NUT, 4-40 2 33 402837 . BRACKET 1
9 060579 . DOWEL PIN, 1/4 X 15/16 2 34 402839 . TUBE 1
10 060942 . ROLL PIN, 1/8 X 1-1/4 2 35 402840 . CAM 1
11 061016 . ROLL PIN, 1/4 X 3 2 36 402841 . HANDLE GUARD 1
12 061200-01 . SPIROL PIN, 3/16 X 1 1 37 402843 . PAD 2
13 067416 . PAN HD SCREW, 6-32 X 1/2 4 38 504538-01 . SWITCH WIRE ASSEMBLY 3
14 068189 . RD HD SCREW, 4-40 X 1-7/8 2 39 505052 . SWITCH BRACKET 1
15 069462 . FLAT HD SLOTTED SCREW, 2 40 800272 . CONTROL LEVER 2
6-32 X 3/4 41 800273 . CONTROL HANDLE 1
16 069463 . FLAT HD SLOTTED SCREW, 2 42 800274 . SAFETY COVER 1
6-32 X 1 43 020697 . PUSHBUTTON SWITCH 2
17 069478 . PHILIPS FLAT HD SCREW, 4 44 020699 . CUTOUT SWITCH, HIGH SPEED 1
1/4-20 X 3/4
45 020776 . HORN PUSHBUTTON SWITCH 1
18 069715 . SOCKET FLAT HD SCREW, 2
46 023171 . WIRE HARNESS ASSEMBLY 1
1/4-20 X 3/4
47 056618 . HIGH SPEED DECAL 1
19 070486 . RD HD SLOTTED, MACHINE 2
48 056619-03 . LIFT DECAL 1
SCREW
49 056619-04 . LOWER DECAL 1
20 072400-01 . SLOTTED HEX SCREW, 4
6-32 X 1/2 50 056624 . HORN DECAL 1
21 072415 . PAN HD SCREW, THREAD 1 51 067415 . PAN HD SCREW, 6-32 X 1/4 4
CUTTING, 4-40 X 5/8 52 067416 . PAN HD SCREW, 6-32 X 1/2 4
22 073461 . SOCKET SET SCREW 2 53 068190 . PHILLIPS PAN HD SCREW 2
23 074711 . CONNECTING ROD SPACER 1 54 402833 . TOP COVER 1
24 075088 . RETURN SPRING 1 55 402842 . SWITCH PLATE 1

PTW1104 7-3
 R5099

Figure 7-2 Control Head Assembly - Transistor

7-4 PTW1104
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505360-04 CONTROL HEAD 1 30 073461 . SOCKET SET SCREW 2
1 005652 . PIN HOUSING 1 31 074711 . CONNECTING ROD SPACER 1
2 505317 . RESISTOR ASSEMBLY 1 32 075088 . RETURN SPRING 1
3 017580 . POTENTIOMETER 1 33 075510 . COMPRESSION SPRING 2
4 018202 . SWITCH INSULATOR 1 34 077007 . WASHER 5
5 020669 . MICRO SWITCH 2 36 077204 . SPLIT LOCK WASHER #6 4
6 505323 . POTENTIOMETER WIRE 1 37 400546 . CONNECTING ROD ASSEMBLY 2
HARNESS 38 402827 . SHAFT 1
7 020775 . MICRO SWITCH 2 39 402828 . CAP 2
8 052956 . FLANGED BEARING 2 40 402830 . COVER 1
9 053366 . RETURN SPRING 1 41 403358 . TUBE 2
10 056131 . HOSE CLAMP 1 42 074724 . SPACER 1
11 056617 . FORWARD-REVERSE DECAL 1 43 402836 . SPACER 2
12 057262 . POTENTIOMETER DISK 1 44 402837 . BRACKET 1
13 059633 . HEX LOCK NUT, 2-56 2 45 402839 . TUBE 1
14 059634 . HEX LOCK NUT, 4-40 2 46 402840 . CAM 1
15 060579 . DOWEL PIN, 1/4 X 15/16 2 47 402841 . HANDLE GUARD 1
16 060942 . ROLL PIN, 1/8 X 1-1/4 2 48 402843 . PAD 2
17 061016 . ROLL PIN, 1/4 X 3 2 49 504538-01 . WIRE ASSEMBLY 5
18 061200-01 . SPIROL PIN, 3/16 X 1 1 50 505052 . SWITCH BRACKET ASSEMBLY 1
19 061750 . “E” RETAINER RING 2 51 066052 . THUMB SCREW, 6-32 1
20 067416 . PAN HD SCREW, 6-32 X 1/2 4 52 800272 . CONTROL LEVER 2
21 068180 . ROUND HD SCREW, 4-40 X 1-1/2 2 53 800273 . CONTROL HANDLE 1
22 069462 . FLAT HD SLOTTED SCREW, 2 54 800274 . COVER 1
6-32 X 3/4 55 023201 . WIRE HARNESS 1
23 069463 . FLAT HD SLOTTED SCREW, 2 56 020697 . PUSHBUTTON SWITCH 2
6-32 X 1
57 020699 . CUTOUT SWITCH, HIGH SPEED 1
24 069478 . PHILIPS FLAT HD SCREW, 4
58 020776 . HORN PUSHBUTTON SWITCH 1
1/4-20 X 3/4
59 056618 . HIGH SPEED DECAL 1
25 069715 . SOCKET FLAT HD SCREW, 2
60 056619-03 . LIFT DECAL 1
1/4-20 X 3/4
61 056619-04 . LOWER DECAL 1
26 070486 . PAN HD SCREW, BRASS 2
62 056624 . HORN DECAL 1
27 072400-01 . SLOTTED HEX SCREW, 4
6-32 X 1/2 63 067415 . PAN HD SCREW, 6-32 X 1/4 4

28 072415 . PAN HD SCREW, THREAD 1 64 067416 . PAN HD SCREW, 6-32 X 1/2 4

CUTTING, 4-40 X 5/8 65 068190 . PHILLIPS PAN HD SCREW 2
29 072415 . PAN HD SCREW, THREAD 1 66 402833 . TOP COVER 1
CUTTING, 4-40 X 5/8 67 402842 . SWITCH PLATE 1

PTW1104 7-5
 R5846

Figure 7-3 Steering Arm

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505765-01 CONTROL ARM ASSY 1 11 071377 . SCREW, 10-32 X 3/4 3
1 065569 . SCREW, 7/16-14 X 2-1/4 1 12 056200 . CLEVIS 1
2 401127 . SPACER 1 13 800275 . HANDLE 1
3 504364 . CLAMP ASSY 1 14 285302 . PIN SPRING 1
4 501371 . HOUSING SPRING 1 15 285303 . PIN SPRING 1
5 075060 . SPRING 1 16 800204 . CLAMP 1
6 059426 . NUT, HEX, 5/16-18 2 17 402363 . ARM, PIVOT 1
7 077210 . WASHER, LOCK, SPLIT, 5/16 2 18 052925 . . BEARING FLANGED 1
19 052922 . . BEARING FLANGED 1
8 060417 . PIN, COTTER 2 20 501673 . ROD, BRAKE 1
9 060300 . PIN, CLEVIS 1 21 069478 . SCREW, PHILLIPS FLAT HEAD, 1
10 052876 . BUMPER 2 1/4-20 X 3/4

7-6 PTW1104
 INDEX PART NO.
NO. NO. PART NAME 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 REF
(FIGURE 7-6)

Figure 7-4 Pivot Tube Assembly

PTW1104 7-7
 R5144

Figure 7-5 Brake and Linkage

7-8 PTW1104
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 053109 BUSHING, LOCK 2 17 800188 PIN, LINK 1
2 060417 PIN, COTTER, 3/32 X 3/4 5 18 052821 DISC BRAKE ASSY 1
3 053106 BUSHING, FLANGED 1 19 059421 NUT 2
4 111104 PLATE, UPPER PIVOT 1 20 901189 BOLT 2
5 060320 PIN, CLEVIS 1 21 901190 SPACER 2
6 060321 PIN, CLEVIS 1 22 901191 SPRING 2
7 505532 WELDMENT, BRAKE ROD 1 23 901188 PAD, BRAKE 1
8 503523 BRACKET 1 24 901198 E-RING 1
9 077209 WASHER, LOCK, SPLIT, 1/4 5 25 901197 WASHER 1
10 063482 SCREW 2 26 901196 SPRING 1
11 403182 BLOCK, MOUNTING 2 27 901192 PAD, BRAKE, WITH PIN 1
12 063477 SCREW, CAP, HEX HEAD 3 28 901195 BRACKET 1
1/4-20 X 5/8) 29 901194 LEVER 1
13 400804 PIN 1 30 901193 WASHER 1
14 077011 WASHER, FLAT, 5/16 1 31 077209 WASHER, LOCK, SPLIT, 1/4 2
15 505232 LEVER, BRAKE 1 32 — BRAKE, DISC (FIGURE 7-6) REF
16 403179 PIN 1 33 403378 SPACER 1

PTW1104 7-9
 R5311

Figure 7-6 Transmission Assembly

7-10 PTW1104
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505233 TRANSMISSION ASSEMBLY 25 051216 . . BEARING, NEEDLE 1
1 — . DRIVE MOTOR (FIGURE 7-7) 1 26 051208 . . THRUST, BEARING, NEEDLE 1
2 063557 . BOLT, 5/16-18 X 1-1/4 4 27 057256 . . GEAR AND SHAFT 1
3 077210 . WASHER, SPLIT, 5/16 4 28 057241 . . GEAR 1
4 403181 . MOTOR PLATE 1 29 053031 . . BEARING, THRUST 1
5 065453 . SCREW, CAP, SOC HEAD 3 30 251204 . . BEARING NEEDLE 1
10-32 X 1 31 051203 . . BEARING NEEDLE 2
6 057906 . KEY 1 32 051207 . . THRUST, BEARING, NEEDLE 2
7 505256 . DISC ASSEMBLY 1 33 050711 . . SHAFT 1
8 — . BEARING, BALL 1 34 051217 . . BEARING, THRUST 4
9 042132 . O-RING, 1.3 IN. DIA. 1 35 053028 . . BEARING, THRUST 2
10 400683 . HOUSING, MOTOR BEARING 1 36 073516 . . SEAL 1
11 042131 . O-RING, 1.6 IN. DIA. 1 37 051215 . . BEARING, THRUST 2
12 073517 . SEAL 1 38 — . . NOT USED
13 505710-01 . WHEEL AND HUB ASSEMBLY 1 39 057908 . . KEY 1
(STD) 40 057242 . . GEAR, SPUR 1
14 052764 . BOLT 5 41 061731 . . RING, SNAP, EXT, 1-3/8 1
15 063495 . SCREW, HEX HEAD 2 42 036115 . . GASKET 1
1/4-20 X 1/2
43 800184 . . COVER 1
16 — . PIVOT TUBE AND PLATE REF
44 060609 . . PIN 2
ASSEMBLY (FIGURE 7-4)
45 063482 . . SCREW, 1/4-20 X 1-1/4 14
— 901362 . GEARBOX ASSEMBLY 1
46 077209 . . WASHER, LOCK, 1/4 14
TRANSMISSION
47 026310 . . PLUG 1
17 057237 . . GEAR, SPUR 1
48 076702 . . VENT, TRANSMISSION 1
18 060974 . . PIN, ROLL 1
49 800176 . . HOUSING, TRANSMISSION 1
19 026302 . . PLUG 1
50 057238 . . GEAR, SPUR 1
20 051206 . . THRUST, BEARING, NEEDLE 2
51 057909 . . KEY 3
21 051202 . . BEARING 2
52 057257 . . GEAR AND SHAFT 1
22 306808 . . SPACER 1
53 077208 . . WASHER, LOCK, 3/16 3
23 057240 . . GEAR, SPUR 1
54 060609 . . PIN 2
24 057258 . . GEAR AND SHAFT 1

PTW1104 7-11
 USED ON TRUCKS
SERIAL NUMBERS
PRIOR TO 371794

R5312

Figure 7-7 Drive Motor Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016046 MOTOR, DRIVE 1 7 901268 . TERMINAL KIT 1
1 901264 . COIL SET, FIELD 1 8 — . WASHER, LOCK, 1/4 4
2 901265 . ARMATURE 1 9 — . SCREW, FILLISTER HEAD, 4
3 901266 . BEARING, COMMUTATOR END 1 10-32 X 3/4
10 901269 . HOLDER, BRUSH 1
4 900450 . BRUSH (SET OF TWO) 1
11 — . SCREW, PLOE SHOE, 1
5 901451 . SPRING, BRUSH (SET OF TWO) 1
3/8-16 X 1/2
6 901267 . HEAD, COMMUTATOR END 1

7-12 PTW1104
 USED ON TRUCKS
SERIAL NUMBERS
371794 TO 376836

R6109

Figure 7-8 Drive Motor Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016052 MOTOR, DRIVE 1 5 — . FIELD RING 1
1 907176 . ARMATURE 1 6 907177 . BRUSH SET 1
2 901266 . BEARING, COMMUTATOR END 1 7 907178 . SPRING SET 1
3 — . FIELD COILS 1 8 907179 . BRUSH HOLDER 1
4 — . POLE SHOES 2 9 907180 . HEAD, COMMUTATOR 1

PTW1104 7-13
 R5313

Figure 7-9 Base and Frame

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 505528 COVER 1 7 077030 WASHER, FLAT NO. 1/4 8
2 059925-01 NUT, U-CLIP 2 8 403695 COVER, RH 1
3 063482 SCREW, HEX HEAD, 2 9 077031 WASHER, FLAT NO. 1/4 2
1/4-20 X 1-1/4 10 059421 NUT, HEX, 1/4-20 2
4 077209 WASHER, SPLIT, LOCK, 1/4 12 11 505702-01 FRAME, POWER SECTION 1
5 403694 COVER, LH 1 12 060965 PIN, ROLL 2
6 070477 SCREW, RD HD PHILLIPS, 8
1/4-20 X 5/8

7-14 PTW1104
 NOTES

PTW1104 7-15
 R5314

Figure 7-10 Fork Section Assembly

7-16 PTW1104
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 505706-01 FORK SECTION WELDMENT 1 14 505614-02 ROD END, FRONT (42” LG FORK) 2
(48” LG X 27 W) 14 505614-03 ROD END, FRONT (36” LG FORK) 2
1 505706-02 FORK SECTION WELDMENT 1 15 052948-03 . BEARING, SLEEVE 2
(42” LG X 27 W) 16 505615-01 ROD END, REAR 2
1 505706-03 FORK SECTION WELDMENT 1 17 052948-01 . BEARING, SLEEVE 2
(36” LG X 27 W) 18 059444 NUT, HEX 2
1 505706-04 FORK SECTION WELDMENT 1
19 077215 WASHER, LOCK 2
(48” LG X 22 W)
20 402501 TURNBUCKLE 2
2 075085 SPRING, EXTENSION 4
21 075085 SPRING, EXTENSION 4
3 061200-02 PIN, SPIROL 2
22 402431-02 SHAFT 4
4 402432 SHAFT, PILOT 4
23 061200-01 PIN, SPIROL 6
5 061200-04 PIN, SPIROL 1
24 505534 PIVOT, WELDMENT 2
6 505709 WHEEL ASSY, POLY 2
25 052948-02 BEARING SLEEVE 4
7 051136 . BEARING, BALL 2
26 504708 ROLLER ASSY 2
8 077033 WASHER, FLAT 4
27 052948-01 . BEARING, SLEEVE 2
9 505708 HOUSING, WHEEL 2
28 403511-01 SHAFT, PIVOT 2
10 052948-03 . BEARING, SLEEVE 2
29 403505 ROLLER 4
11 403687 SHAFT, AXLE 2
30 053012 WASHER, THRUST, 3/32” THK AR
12 402431-01 SHAFT 2
30 053013 WASHER, THRUST, 1/2” THK AR
13 077063 WASHER, FLAT 24
30 053013 WASHER, THRUST, 5/32” THK AR
14 505614-01 ROD END, FRONT (48” LG FORK) 2
30 053014 WASHER, THRUST, 3/16” THK AR

PTW1104 7-17
 R5324

Figure 7-11 Hydraulic System Installation

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 063603 SCREW, HEX HEAD CAP 2 9 026922 ADAPTER, STRAIGHT 1
2 077211 WASHER, LOCK 2 10 505582 CYLINDER ASSY, HYD 1
(SEE FIGURE 7-13)
3 077011 WASHER, FLAT 2
4 065476 SCREW, HEX HEAD CAP, 1 11 063705 SCREW, HEX HEAD CAP 2
1/4-20 X 1/2 12 077213 WASHER, LOCK 2
5 077209 WASHER, LOCK, 1/4 1 13 505529 MOUNT, CYLINDER 1
6 077031 WASHER, FLAT 1 14 016594 PUMP AND MOTOR ASSY 1
(SEE FIGURE 7-12)
7 403699 GUIDE, CYLINDER 1
8 504732-01 HOSE ASSY 1

7-18 PTW1104
 R4356

Figure 7-12 Pump, Motor and Reservoir Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 901432 CAP/BRUSH KIT 1 9 901438 O-RING 1
2 901433 24V MOTOR 1 10 901439 COUPLING 1
3 020715 24V SOLENOID 1 11 901440 FILTER 1
4 901434 MOTOR ADAPTER 1 12 901441 RESERVOIR 1
5 048133 SOLENOID RELEASE VALVE 1 13 026703 ELBOW 1
6 901435 FLOW REGULATOR 1 14 901442 RELIEF VALVE ASSY 1
7 901436 CHECK VALVE 1 15 076701 BREATHER PLUG 1
8 901437 ADAPTER-PUMP-RES KIT 1 16 025535 ELBOW, 9/16 1

PTW1104 7-19
 PACKING KIT
901498 CONTAINS:
ITEM QTY
1 1
2 1
4 1

R5325

Figure 7-13 Hydraulic Cylinder Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505582 CYLINDER ASSEMBLY, REF 3 — . HEAD, CYLINDER 1
HYDRAULIC 4 042153 * . O-RING 1
1 049514 * . RING, WIPER 1 5 — . ROD 1
2 043134 * . SEAL, HEAD 1 6 — . CYLINDER WELDMENT 1
* INCLUDED IN PACKING KIT, PN 901498, FOR ONE
CYLINDER

7-20 PTW1104
 R5315

Figure 7-14 Storage and Batteries and Connector

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 005450 HANDLE, BATTERY CONNECTOR 1 7 003149 BATTERY, STORAGE, 12V 2
200 AH, DRY
2 505549 CABLE ASSEMBLY, BATTERY 1
3 070476 SCREW, MACHINE, RD HEAD 1 7 003148 BATTERY, STORAGE, 12V 2
200 AH, WET
4 077209 WASHER, LOCK 1
8 056133 WIRE TIE A/R
5 056139 CLAMP 1
9 505598-02 * SPACER INSTL., BATTERY, 1
6 505548 CABLE ASSEMBLY, BATTERY 1
155 AH
JUMPER
9 505598-03 * SPACER INSTL., BATTERY, 1
7 003217 BATTERY, STORAGE, 12V 2
200 AH
155 AH, DRY
7 003217-01 BATTERY, STORAGE, 12V 2
200 AH, WET
* NOT SHOWN

PTW1104 7-21
 1
3

R5695

Figure 7-15 Quick Disconnect Cable Installation

INDEX PART NO.

NO. NO. PART NAME REQD.
— 505634 QUICK DISCONNECT CABLE KIT
1 505622 CONNECTOR ASSEMBLY 4
BATTERY
2 505633 CONNECTOR ASSEMBLY 1
BATTERY
3 505649 CORD ASSY-CHARGING, 1
EXTERNAL

7-22 PTW1104
 R5320

Figure 7-16 Horn Installation

INDEX PART NO.

NO. NO. PART NAME REQD.
1 059421 NUT, HEX 1
2 077209 WASHER, LOCK 1
3 077031 WASHER, FLAT 1
4 504096 SUPPRESSOR, SPIKE 1
(TRANSISTOR TRUCKS
ONLY)
5 009602 HORN, WARNING, 24V 1

PTW1104 7-23
 R5316

Figure 7-17 Electrical Installation, Resistor

INDEX PART NO.

NO. NO. PART NAME 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
6 077211 WASHER, LOCK 4
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 1
(SEE FIGURE 7-21)

7-24 PTW1104
 R5318

Figure 7-18 Electrical Installation, Transistor

INDEX PART NO.

NO. NO. PART NAME 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
6 077211 WASHER, LOCK 4
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 1
(SEE FIGURE 7-21)
12 504116 SPIKE SUPPRESSOR ASSEMBLY 1
13 504097 SPIKE SUPPRESSOR ASSEMBLY 1

PTW1104 7-25
 R5516

Figure 7-19 PTW Battery Charger Installation

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 021204 TERMINAL, SLIP ON 1 15 004978 CHARGER, 120 VAC 1
2 077211 WASHER, LOCK, 3/8 SPLIT 1 15 004980 CHARGER, 240 VAC 1
3 059429 NUT, HEX, 3/8-16 1 16 901603 . CIRCUIT BOARD WITH HEAT 1
SINK
4 059421 NUT, HEX, 6-32 1
17 901604 . CIRCUIT BREAKER 1
5 021206 TERMINAL, RING 1
6 505675-02 WIRE, ELECTRICAL A/R 18 900379 . INDICATOR LIGHT 1
(PART OF ITEM 15)
7 403688 SHIM, BATTERY CONNECTOR 1
19 005802 CORD, CHARGER 1
8 077209 WASHER, LOCK, 1/4 SPLIT 3
120 VAC, 10 FT
9 065476 SCREW, HEX HD 1
19 505712 CORD, CHARGER 1
10 063482 SCREW, MACHINE 2 240 VAC, 10 FT
11 021718 TERMINAL, SLIP-ON 3 20 505597 CONNECTOR ASSEMBLY 1
12 505674-01 FUSE HOLDER ASY 1 21 015609 AMMETER 1
13 008910 FUSE, 15 AMP 1 22 005433 CONNECTOR, INLINE 1
14 077064 WASHER, FLAT 2

7-26 PTW1104
 NOTES

PTW1104 7-27
 R5317

Figure 7-20 Contactor Panel Assembly, Resistor

7-28 PTW1104
 INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505544 PANEL ASSEMBLY, RESISTOR REF 20 059416 . NUT, HEX 5
1 504611-28 . CABLE ASSEMBLY, 2 21 023222 . WIRE HARNESS ASSEMBLY 1
F1 AND F2 22 403550 . BUS BAR 1
2 504611-18 . CABLE ASSEMBLY, TO MAIN 1 23 075623-01 . STUD 2
FUSE 24 — NOT USED
3 504611-26 . CABLE ASSEMBLY, TO PUMP 1 25 075623-06 . STUD 2
POSITIVE 26 403547 . PANEL, CONTACTOR 1
4 403549 . BUSS BAR 2
27 504611-32 . CABLE ASSEMBLY, TO 1
5 403548 . BUSS BAR 2 RESISTOR
5 074805 . SPINDLE 4 28 402256 . MOUNT RESISTOR 2
6 005667 . SOLENOID-CONTACTOR, 24V 2 29 018911 . RESISTOR 1
DIRECTIONAL
30 504611-30 . CABLE ASSEMBLY, A1 1
7 070478 . SCREW, MACHINE, RD HEAD 9
31 504611-33 . CABLE ASSEMBLY, PUMP NEG 1
8 504611-27 . CABLE ASSEMBLY, A2 1 32 504611-03 . CABLE ASSEMBLY, TO 1
9 008904 . FUSE HOLDER 1 RESISTOR
10 008910 . FUSE, 15 A 1 33 077007 . WASHER, FLAT 3
11 077203 . WASHER, LOCK 1 34 — NOT USED
12 068179 . SCREW 1 35 059421 . NUT, HEX 10
13 056504 . DECAL, 15 A FUSE 1 36 077209 . WASHER, LOCK 12
14 005668 . SOLENOID - CONTACTOR 2 37 077031 . WASHER, FLAT 2
24V SPEED
38 010614 . STANDOFF, INSULATOR 2
15 504611-31 . CABLE ASSEMBLY, TO 1 39 056562 . DECAL, FUSE 120 A 1
RESISTOR
40 008918 . FUSE, 120 1
16 505596-01 . TIME DELAY ASSEMBLY 1
41 070489 . SCREW, MACHINE 2
17 056121 . CLAMP 1
42 077105 . WASHER, BRONZE 4
18 071376 . SCREW 4
43 505546-01 . CONNECTOR ASSEMBLY, 1
19 077207 . WASHER, LOCK 6
BATTERY

PTW1104 7-29
 USED ON TRUCKS
SERIAL NUMBERS
PRIOR TO 338607

R5319

Figure 7-21 Contactor Panel Assembly, Transistor

7-30 PTW1104
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505553 PANEL ASSEMBLY REF 19 070477 . SCREW, MACHINE, RD HEAD 3
CONTACTOR, TRANSISTOR 20 077209 . WASHER, LOCK 11
1 005996 . DIODE ASSEMBLY 2 21 059421 . NUT, HEX 9
2 504611-28 . CABLE ASSEMBLY, F1 AND F2 2 22 010610 . PAD, INSULATOR 1
3 403549 . BUSS BAR 2 23 505320 . DIODE ASSEMBLY 1
4 403548 . BUSS BAR 2 24 077007 . WASHER, FLAT 2
5 005667 . SOLENOID-CONTACTOR, 2 25 068177 . SCREW, MACHINE, RH HEAD 2
24V - DIRECTIONAL 26 505321 . SUPPRESSOR ASSEMBLY 1
6 504611-36 . CABLE ASSEMBLY 1 27 018409-02 . RELAY, 24V 1
CONTACTOR TO
28 056113 . WIRE TIE 3
CONTROLLER
29 056111 . WIRE TIE 2
7 008904 . FUSEHOLDER 1
30 070477 . SCREW, MACHINE, RD HEAD 4
8 008910 . FUSE, 15A 1
31 005467-02 . CONTROLLER, SPEED 1
9 077203 . WASHER, LOCK 3
32 504611-31 . CABLE ASSEMBLY, MAIN 1
10 068179 . SCREW, MACHINE, RD HEAD 1
FUSE TO CONTROLLER
11 056504 . DECAL, FUSE, 15 A 1
33 — . NOT USED
12 504611-24 . CABLE ASSEMBLY 1
34 008918 . FUSE, 120 A 1
CONTACTOR TO
35 056562 . DECAL, FUSE, 120 A 1
CONTROLLER
36 070489 . SCREW, MACHINE, RD HEAD 2
13 504611-29 . CABLE ASSEMBLY, A1 1
BRASS
14 504611-04 . CABLE ASSEMBLY, TO PUMP 2
37 010614 . STANDOFF, INSULATOR 2
NEGATIVE/POS
38 077105 . WASHER, BRONZE 4
15 075623-01 . STUD 2
39 023225 . WIRE HARNESS ASSEMBLY 1
16 504611-27 . CABLE ASSEMBLY, A2 1
40 505546-02 . CONNECTOR ASSEMBLY, 1
17 075623-06 . STUD 2
BATTERY
18 403547 . PANEL, CONTACTOR 1

PTW1104 7-31
 USED ON TRUCKS
SERIAL NUMBERS
338608 TO 373233

R4133

Figure 7-22 Contactor Panel Assembly, E Rated Transistor

7-32 PTW1104
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505430 PANEL ASSEMBLY REF 22 005422 CONNECTOR-INLINE, INSUL 2
CONTACTOR, TYPE E 23 008918 FUSE-120 AMP 1
TRANSISTOR 24 056562 DECAL-FUSE 120 AMP 1
1 005467-02 . 24V SPEED CONTROLLER 1 25 010614 STANDOFF-INSULATOR 2
2 005667 . 24V CONTACTOR, FWD/REV 2 26 077105 WASHER-BRONZE 4
3 018409-02 . 24V FLANGE MOUNTED RELAY 1 27 070489 SCREW-RD HD, BRASS 2
4 505424 . TRANSISTOR PANEL 1 SLOTTED
5 068177 . SCREW-RD HD, #5-40 X 3/8 4 28 069477 SCREW-PH, FL HD, 1/4-20 X 1/2 2
6 077203 . WAHSER-LOCK, SPLIT, #5 5 29 063552 SCREW-HEX CAP, 5/16-18 X 5/8 2
7 077007 WASHER 6 30 059426 NUT-HEX, 5/16-18 4
8 505321 SUPPRESSOR ASSY 1 31 077210 WASHER-LOCK, SPLIT, 5/16 4
9 070475 SCREW-PH RD HD, 1/4-20 X 3/8 4 32 063553 SCREW-HEX CAP, 5/16-18 X 3/4 2
10 077209 WASHER-LOCK, SPLIT, 1/4 6 33 005976 DIODE 2
11 505320 DIODE ASSY 1 34 010613 TUBING-INSULATING A/R
12 010610 PAD-INSUL, DIODE 1 35 505447 CONNECTOR ASSY, BATTERY 1
13 401181 BUSSBAR 2 36 504611-18 CABLE ASSEMBLY (M-) 1
14 070491 WASHER 4 37 504611-19 CABLE ASSEMBLY (A2) 1
15 077205 WASHER-LOCK, SPLIT, #8 4 38 504611-20 CABLE ASSEMBLY (POS) 1
16 077032 WASHER, 3/16 X 1/2 X 13 GA 4 39 504611-22 CABLE ASSEMBLY 1
17 008910 FUSE-15 AMP 1 40 504728-06 CABLE ASSEMBLY 1
18 008904 FUSEHOLDER FOR 008910 1 41 504728-01 CABLE ASSEMBLY 1
(15AMP FUSE) 42 504611-23 CABLE ASSEMBLY 1
19 068179 SCREW-RD HD, #5-40 X 5/8 1 43 504611-24 CABLE ASSEMBLY 1
20 056504 DECAL-FUSE, 15A 1 44 504728-02 CABLE ASSEMBLY 1
21 023215 BATTERY CONNECTOR ASSY 1

PTW1104 7-33
 USED ON TRUCKS
SERIAL NUMBERS
373234 TO 376836

R6130

Figure 7-23 Contactor Panel Assembly, E Rated Transistor

7-34 PTW1104
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
505903 PANEL ASSY., ELEC. REF 17 059426 NUT-HEX, 5/16-18 4
1 403837 PANEL WELDMENT 1 18 056504 DECAL - FUSE 15 AMP 1
2 907200-02 CONTROLLER - SPEED, 24V, 2 19 068179 SCREW - PH RD HD, #5-40 x 5/8 1
PREPROGRAMMED 20 077203 WASHER - LOCK, SPLIT, #5 1
3 070478 SCREW - PH RD HD, 1/4-20 x 3/4 3 21 008910 FUSE - 15 AMP 1
4 077209 WASHER - LOCK, SPLIT, 1/4 10 22 008904 FUSE HOLDER 1
5 059421 NUT - HEX, 1/4-20 8 23 005667 CONTACTOR - DIRECTIONAL, 2
6 070477 SCREW - PH RD HD, 1/4-20 x 5/8 3 SOLENOID, 24v
7 005996 DIODE ASY - CONTACTOR 2 24 403548 BUS BAR 2
8 505546-02 CONNECTOR ASSY, BATTERY 1 25 403549 BUS BAR 2
9 077105 WASHER, BRASS 4 26 075623-06 STUD - PRESS IN, 1/4-20 X 1-1/4 2
10 070489 SCREW - RH HD, BRASS, 2 27 075623-01 STUD - PRESS IN, 1/4-20 X 1/2 2
SLOTTED 28 504611-27 CABLE ASY 1
11 008918 FUSE - 120 AMP 1 29 504611-04 CABLE ASY 2
12 023256 HARNESS ASSY - PANEL 1 30 504611-36 CABLE ASY 1
13 056562 DECAL - FUSE 120 AMP 1 31 504611-31 CABLE ASY 1
14 010614 STANDOFF - INSULATOR 2 32 504611-44 CABLE ASY 1
15 063553 SCREW - HEX CAP, 4 33 504611-28 CABLE ASY 2
5/16-18 X 3/4 34 504611-34 CABLE ASY 1
16 077210 WASHER - LOCK, SPLIT, 5/16 4

PTW1104 7-35
 R5328
R5332

Figure 7-24 Battery Discharge Indicator - Option Figure 7-25 Key Switch - Option

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 010617-02 INDICATOR, BATTERY 1 1 020725 SWITCH, KEY 1
DISCHARGE, 24V 2 021203 TERMINAL, RING NO. 10 2
2 021718 TERMINAL, SLIP-ON 2 3 021204 TERMINAL, SLIP-ON 2
3 056111 STRAP, TIEDOWN, ELECTRICAL 2 4 005422 CONNECTOR, TAB 2
4 021207 TERMINAL, LUG, RING 2 5 403696 PANEL (NOT SHOWN) 1
5 403696 PANEL (NOT SHOWN) 1

7-36 PTW1104
 R5329

Figure 7-26 Cold Conditioning Package Installation - Option

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 020690 SWITCH, DEADMAN 1 13 018214 INSULATOR 1
2 019910 RELIEF, STRAIN 1 14 072400-01 SCREW 2
3 023135 CABLE ASSY, DEADMAN REF 15 077204 WASHER, LOCK 2
4 056491 DECAL, COLD CONDITIONING 1 16 077007 WASHER 2
5 068186 SCREW 2 17 402829 BRACKET 1
6 059632 NUT, LOCK 2 18 005643 TERMINAL, CONTACT PIN 1
7 403372 INSULATOR 2 19 005649 SPLICE 1
8 020736 SWITCH, THERMAL 1 20 055750 * GREASE A/R
9 400044 BRACKET 1 20 055753 ** GREASE A/R
10 400544 BRACKET, RESISTOR MTG 1 21 055779 * HYDRAULIC OIL A/R
11 018909 10 OHM, 20 WATT HEAT 2 21 055784 ** HYDRAULIC OIL A/R
RESITOR 22 055780 * TRANSMISSION OIL A/R
12 — NOT USED 22 055790 ** TRANSMISSION OIL A/R
A/R - AS REQUIRED

* FOR INTERMITTENT OPERATION BELOW 32 ° F.

** FOR CONTINUOUS OPERATION BELOW 32° F.

PTW1104 7-37
 R5330

Figure 7-27 Hourmeter Installation - Option

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 056111 WIRE TIE 3 8 005993 DIODE ASSEMBLY 2
2 068179 SCREW, MACHINE, ROUND 3 9 077203 WASHER, LOCK, SPLIT, NO. 5 3
HEAD 10 059410 NUT, HEX 5-40 3
3 015604 HOURMETER 1 11 021203 TERMINAL, LUG, RING 1
4 005649 SPLICE, CONNECTOR 2 12 021207 TERMINAL, LUG, RING 1
5 005626 PIN, CONTACT 3 13 021718 TERMINAL, SLIP-ON 1
6 005647 HOUSING, PIN 1 14 403696 PANEL (NOT SHOWN) 1
7 010610 PAD, INSULATING 1

7-38 PTW1104
 R5331

Figure 7-28 Load Backrest - Option

INDEX PART NO.

NO. NO. PART NAME REQD.
1 505563-01 BACKREST WELDMENT, 48” 1
HIGH
2 064707 SCREW, HEX HEAD CAP 4
3 077213 WASHER 4

PTW1104 7-39
 R5641

Figure 7-29 Caster

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 069716 SCREW, 1/2-13 X 1-1/4 8 13 504621 . ARM WELDMENT 1
2 — NOT USED 14 402291 . AXLE 1
3 — NOT USED 15 025713 . FITTING, LUBE 1
4 402365 SHIM A/R 16 051154 . BEARING, THRUST 2
5 — NOT USED 17 051152 . BEARING 2
— 504620-01 CASTER ASSEMBLY 2 18 078263 . WHEEL 1
6 069715 . SCREWHOUSING, PIN 1 19 059645 . NUT, LOCK 1
7 402327 . CLAMP 1 20 077210 . LOCKWASHER, 5/16 2
8 402289 . RACE, BEARING 2 21 063553 . SCREW, 5/16-18 X 3/4 2
9 051404 . HOUSING, BEARING 16 22 402290 . SHAFT 1
10 402292 . HOUSING, BEARING 1 23 053041-01 . BUSHING 2
11 402288 . BASE, CASTER 1 24 061004 . PIN, ROLL 1
12 075075 . SPRING 2 25 025702 . FITTING, LUBE 1

7-40 PTW1104
Big Joe Manufacturing Company