Bo PDF

PTE 45 SERIES
SELF-PROPELLED, PALLET
LIFT TRUCK
Operation
Maintenance
Repair Parts List
Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901361
Rev D 06/18/2008
WARNING
Do not operate this truck unless you have been autho- Always look in direction of travel. Keep a clear view,
rized and trained to do so, and have read all warnings and when load interferes with visibility, travel with load
and instructions in Operator’s Manual and on this trailing.
truck.
Use special care when operating on ramps travel
Do not operate this truck until you have checked its slowly, and do not angle or turn. Travel with lifting
condition. Give special attention to tires, horn, battery, mechanism downhill.
controller, lift system, brakes, steering mechanism, Do not handle loads which are higher than the load
guards and safety devices. backrest or load backrest extension unless load is
Operate truck only from designated operating position. secured so that no part of it could fall backward.
Do not carry passengers. Keep feet clear of truck and Before lifting, be sure load is centered, forks are com-
wear foot protection. pletely under load, and load is as far back as possible
Observe applicable traffic regulations. Yield right of against load backrest.
way to pedestrians. Slow down and sound horn at When leaving truck, neutralize travel control, fully
cross aisles and wherever vision is obstructed. lower lifting mechanism and set brake. When leaving
truck unattended, also shut off power.
Start, stop, travel, steer and brake smoothly. Slow
down for turns and on uneven or slippery surfaces that
could cause truck to slide or overturn. Use special
care when traveling without load as the risk of overturn
may be greater.
TABLE OF CONTENTS
Section Page Section Page

1 DESCRIPTION ............................................................1-1 5-1.4. DIRECTIONAL SWITCH REMOVAL AND
1-1. INTRODUCTION. .............................................1-1 ADJUSTMENT................................................. 5-1
1-2. GENERAL DESCRIPTION...............................1-1 5-1.5. POTENTIOMETER REMOVAL TESTING
1-3. SAFETY FEATURES. ......................................1-2 AND ADJUSTMENT. ....................................... 5-4
5-1.6. CONTROL HEAD INSTALLATION.................. 5-5
2 OPERATION ...............................................................2-1 5-2. STEERING ARM ............................................. 5-5
2-1. GENERAL. .......................................................2-1 5-2.1. RETURN SPRING REPLACEMENT. .............. 5-5
2-2. OPERATING PRECAUTIONS. ........................2-1 5-3. BATTERY INDICATOR REPLACEMENT........ 5-5
2-3. BEFORE OPERATION.....................................2-1
2-4. GENERAL CONTROL OPERATION................2-4 6 BRAKE SERVICING ................................................... 6-1
2-5. DRIVING AND STOPPING PROCEDURES. ...2-4 6-1. BRAKES. ......................................................... 6-1
2-6. BELLY-BUTTON SWITCH. ..............................2-4 6-1.1. ADJUSTMENT................................................. 6-1
2-7. STEERING ARM RETURN SPRING. ..............2-5 6-1.2. BRAKE SHOE REPLACEMENT. .................... 6-1
2-8. LIFT AND LOWER CONTROLS. .....................2-5
2-9. LOADING AND UNLOADING. .........................2-5 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL,
2-10. PARKING. ........................................................2-5 SKID BAR AND ENTRY/EXIT ROLLER SERVICING 7-1
7-1. DRIVE WHEEL. ............................................... 7-1
3 PLANNED MAINTENANCE ........................................3-1 7-2. TRANSMISSION. ............................................ 7-1
3-1. GENERAL. .......................................................3-1 7-3. LOAD WHEEL. ................................................ 7-1
3-2. MONTHLY AND QUARTERLY CHECKS. .......3-1 7-3.1. REMOVAL ....................................................... 7-1
3-3. BATTERY CARE. ............................................3-1 7-3.2. REPAIR .......................................................... 7-3
3-4. CHARGING BATTERIES .................................3-1 7-3.3. LOAD WHEEL INSTALLATION....................... 7-3
3-4.1. REMOVING BATTERIES FROM CHARGER ..3-2 7-4. SKID BAR ........................................................ 7-3
3-5. LUBRICATION. ................................................3-3 7-5. ENTRY AND EXIT ROLLERS ......................... 7-4
7-5.1. ENTRY ROLLER REPLACEMENT ................. 7-4
4 TROUBLESHOOTING ................................................4-1 7-5.2. EXIT ROLLER REPLACEMENT ..................... 7-5
4-1. GENERAL ........................................................4-1
4-2. BATTERY CHARGER TROUBLESHOOTING 4-3 8 ELEVATION SYSTEM SERVICING ........................... 8-1
4-2.1. DIP SWITCH SETTING....................................4-3 8-1. GENERAL........................................................ 8-1
4-2.2. THERMISTOR..................................................4-3 8-2. LIFT LINKAGE ................................................. 8-1
4-2.3. CIRCUIT BREAKER TESTING ........................4-3 8-2.1. REMOVAL ....................................................... 8-1
4-2.4. POWER TRANSFORMER TESTING...............4-3 8-2.2. REASSEMBLY ................................................ 8-1
4-2.5. CIRCUIT BOARD TESTING.............................4-4 8-3. POWER SECTION AND FORK SECTION...... 8-1
4-3. TRANSISTOR CONTROLLER 8-3.1. SEPARATING POWER SECTION AND
TROUBLESHOOTING .....................................4-5 FORK SECTION. ............................................. 8-1
4-3.1. FAULT DETECTION. .......................................4-5 8-3.2. FRAME REPAIR. ............................................. 8-2
4-3.2. HAND HELD PROGRAMMER (OPTIONAL)....4-6 8-3.3. CARRIER FRAME REPAIR............................. 8-2
4-3.3. FAULT RECORDING. ......................................4-6 8-3.4. MATING POWER SECTION AND FORK
4-3.4. FAULT RECOVERY. ........................................4-6 SECTION......................................................... 8-2
4-3.5. GENERAL CHECKOUT. ..................................4-6
4-3.6. ADJUSTMENT .................................................4-7 9 HYDRAULIC SYSTEM SERVICING........................... 9-1
4-3.7. DIAGNOSTICS AND TROUBLESHOOTING. ..4-7 9-1. LINES AND FITTINGS .................................... 9-1
4-3.8. PROGRAMMER DIAGNOSTICS .....................4-8 9-2. HYDRAULIC PUMP, MOTOR, AND
RESERVOIR ASSY ......................................... 9-2
5 STEERING ARM, CONTROL HEAD AND 9-2.1. REMOVAL ....................................................... 9-2
PIVOT SERIVCE .........................................................5-1 9-2.2. DISASSEMBLY AND REASSEMBLY ............. 9-2
5-1. CONTROL HEAD .............................................5-1 9-2.3. INSTALLATION ............................................... 9-2
5-1.1. CONTROL HEAD REMOVAL. .........................5-1 9-2.4. LIFT CYLINDER .............................................. 9-4
5-1.2. BELLY-BUTTON SWITCH REPLACEMENT. ..5-1 9-2.5. HYDRAULIC PRESSURE ADJUSTMENT ...... 9-4
5-1.3. LIFT, LOWER AND HORN SWITCH
REPLACEMENT...............................................5-1
901361 i
TABLE OF CONTENTS - Continued
Section Page Section Page

10 ELECTRICAL COMPONENTS ................................. 10-1 10-5. DRIVE MOTOR. ............................................. 10-6
10-1. BATTERY AND CHARGER ASSEMBLY ...... 10-1 10-5.1.BRUSH INSPECTION AND
10-1.1.BATTERY AND CHARGER ASSEMBLY REPLACEMENT ............................................ 10-6
REMOVAL ..................................................... 10-1 10-5.2.MOTOR REMOVAL ....................................... 10-7
10-1.2.BATTERY REMOVAL AND REPLACEMENT 10-1 10-5.3.MOTOR INSTALLATION ...............................10-7
10-1.3. BATTERY CHARGER .................................. 10-1 10-6. LIFT LIMIT SWITCH....................................... 10-7
10-1.4.BATTERY AND CHARGER ASSEMBLY 10-6.1.REPLACEMENT ............................................ 10-7
INSTALLATION ............................................. 10-1 10-6.2.ADJUSTMENT ............................................... 10-7
10-2. ELECTRICAL CONTROL PANEL ................. 10-1 10-7. DEADMAN SWITCH ...................................... 10-7
10-2.1.MAINTENANCE............................................. 10-1 10-7.1.REPLACEMENT ............................................ 10-7
10-2.2.CLEANING .................................................... 10-4 10-7.2.ADJUSTMENT ............................................... 10-7
10-2.3.DIAGNOSTIC HISTORY................................ 10-4
10-2.4.TEST THE FAULT DETECTION CIRCUITRY10-4 11 OPTIONAL EQUIPMENT ..........................................11-1
10-2.5.PANEL REMOVAL. ....................................... 10-4 11-1. LOAD BACKREST. ........................................ 11-1
10-2.6.PANEL DISASSEMBLY................................. 10-4 11-2. CASTERS ...................................................... 11-1
10-2.7.PANEL INSTALLATION. ............................... 10-5 12 ILLUSTRATED PARTS BREAKDOWN .................... 12-1
10-3. HORN REPLACEMENT ................................ 10-5
10-4. PUMP MOTOR. ............................................. 10-6
LIST OF ILLUSTRATIONS
Figure Page Figure Page

1-1 NAME PLATE ...................................................... 1-1 10-2 BATTERY AND CHARGER ASSEMBLY ........... 10-3
1-2 PTE 45 LIFT TRUCK ........................................... 1-1 10-3 ELECTRICAL PANEL......................................... 10-5
2-1 SAMPLE OF OPERATOR CHECK LIST ............. 2-3 10-4 DRIVE MOTOR .................................................. 10-6
2-2 FORWARD/REVERSE CONTROL ...................... 2-4 12-1 STEERING ARM ................................................ 12-2
2-3 PUSHBUTTON SWITCHES ................................ 2-4 12-2 CONTROL HEAD ............................................... 12-4
2-4 BRAKE ACTUATION ........................................... 2-4 12-3 CONTROL HEAD ............................................... 12-5
2-5 BELLY-BUTTON SWITCH ................................... 2-5 12-4 DRIVE ASSEMBLY ............................................ 12-6
3-1 CHARGE INDICATOR ......................................... 3-2 12-5 TRANSMISSION ASSEMBLY............................ 12-7
3-2 LUBRICATION DIAGRAM ................................... 3-4 12-6 DRIVE MOTOR .................................................. 12-8
4-1 DIP SWITCH SETTINGS ..................................... 4-3 12-7 BRAKE ASSEMBLY ........................................... 12-9
4-2 BATTERY CHARGER WIRING DIAGRAM.......... 4-4 12-8 COMPARTMENT ............................................. 12-10
4-3 ELECTRICAL PANEL PARTS ............................. 4-5 12-9 DECALS ........................................................... 12-12
4-4 CONTROLLER TERMINALS ............................... 4-6 12-10 FRAME ............................................................. 12-14
4-5 HAND HELD PROGRAMMER ............................. 4-7 12-11 SKID BAR ASSEMBLY (STANDARD) ............. 12-16
4-6 WIRING DIAGRAM (SHEET 1).......................... 4-12 12-12 CASTER ASSEMBLY (OPTIONAL) ................. 12-18
5-1 CONTROL HEAD SWITCHES............................. 5-2 12-13 LOAD WHEEL ASSEMBLY.............................. 12-20
5-2 CONTROL HEAD AND STEERING ARM............ 5-3 12-14 ENTRY ROLLERS............................................ 12-21
5-3 DRIVE CONTROLS ............................................. 5-4 12-15 LEFT EXIT ROLLERS ...................................... 12-22
6-1 DRIVE ASSEMBLY .............................................. 6-2 12-16 RIGHT EXIT ROLLERS.................................... 12-23
6-2 BRAKE ASSEMBLY............................................. 6-2 12-17 ELECTRICAL PANEL....................................... 12-24
7-1 DRIVE ASSEMBLY .............................................. 7-2 12-18 HYDRAULIC SYSTEM ..................................... 12-25
7-2 WHEEL ASSEMBLY ............................................ 7-3 12-19 PUMP, MOTOR & RESERVOIR ASSEMBLY .. 12-26
7-3 ENTRY ROLLERS ............................................... 7-4 12-20 BATTERY INSTALLATION .............................. 12-28
7-4 LEFT EXIT ROLLERS.......................................... 7-5 12-21 BATTERY AND CHARGER ASSY-
7-5 RIGHT EXIT ROLLERS ....................................... 7-5 TWO 12V BATTERIES..................................... 12-30
8-1 FRAME................................................................. 8-2 12-22 BATTERY AND CHARGER ASSY-
9-1 HYDRAULIC SYSTEM......................................... 9-1 FOUR 6V BATTERIES ..................................... 12-32
9-2 HYDRAULIC POWER UNIT ................................ 9-3 12-23 BACKREST ...................................................... 12-34
10-1 BATTERY AND CHARGER ASSEMBLY........... 10-2 12-24 WIRING COMPONENTS ........................ 12-35
ii 901361
LIST OF TABLES
Table Page Table Page

2-1 OPERATOR CHECKS ............................................2-2 4-1 TROUBLESHOOTING CHART .............................. 4-1
3-1 MONTHLY AND QUARTERLY INSPECTION 4-2 ADJUSTMENT SETTINGS .................................... 4-7
AND SERVICE CHART ..........................................3-1 4-3 LED CODES........................................................... 4-8
3-2 RECOMMENDED LUBRICANTS ...........................3-3 4-4 TROUBLESHOOTING CHART .............................. 4-9
3-3 LUBRICATION CHART ..........................................3-4
901361 iii
SECTION 1
DESCRIPTION
1-1. INTRODUCTION. forks raised of lowered. The lift truck must be pro-
This publication describes the 24 volt transistor tected from the elements.
PTE 45 lift truck distributed by Big Joe Manufacturing The model number will be found on the name plate
Company, Des Plaines, Illinois, 60018. Included are (Figure 1-1) along with the serial number, lifting capac-
operating instructions, planned maintenance instruc- ity, and load center. Figure 1-2 shows the locations of
tions, lubrication procedures, corrective maintenance the truck’s main components and controls.
procedures and a complete parts list with part location
illustrations.
Users shall comply with all requirements indicated in
applicable OSHA standards and current edition of
A.N.S.I. B56.1 Part II. By following these requirements
and the recommendations contained in this manual,
you will receive many years of dependable service
from your Big Joe lift truck.
1-2. GENERAL DESCRIPTION.

The self-propelled PTE 45 truck, Figure 1-2, lifts and
transports payloads up to 4500 pounds on rigid forks.
The forward and reverse motion is controlled by either
of two controller levers mounted on the control head.
Stopping and turning is controlled by the steering arm.
Lift and Lower is controlled by pushbuttons on the con-
trol head. The battery powered lift truck is quiete and
without exhaust fumes.
R6209
The reversible DC motor propels the lift truck in for-
ward or reverse direction throughout the available Figure 1-1 Name Plate
speed range. The PTE 45 lift truck can be driven with
R6451A
Figure 1-2. PTE 45 Lift Truck
901361 1-1
1-3. SAFETY FEATURES. • Separately fused control circuits and power circuits.
The PTE 45 is designed and engineered to provide • Readily accessible HORN button.
maximum safety for operator and payload. Some of
• Slip-resistance hand to provide a firm hand hold for
the safety features incorporated into the design are:
operator.
• Dead-man brake to apply the brake and cut off drive • Flow control valve regulates maximum lowering
power when the steering arm is released. speed within prescribed limits.
• Belly-button switch to reverse truck should the oper-
• Relief valve maintains hydraulic pressure within pre-
ator accidentally pin himself against a wall or
scribed limits.
obstruction when backing up in slow speed.
• High visibility color scheme of truck provides visual
• All control functions automatically return to “OFF”
alert of truck’s presence.
when released.
• Battery Indicator
• Externally accessible quick-disconnect battery plug
within operator's reach. • Casters
1-2 901361
SECTION 2
OPERATION
2-1. GENERAL. • Do not overload truck. Check nameplate for load

This section gives detailed operating instructions for weight and load center information.
the PTE 45 lift truck. The instructions are divided into • Before lifting, be sure load is centered, forks are
the various phases of operations, such as operating completely under load, and load is as far back as
lift, driving, and stopping. Routine precautions are possible against load backrest.
included for safe operation.
• Do not handle loads which are higher than the load
backrest unless load is secured so that no part of it
2-2. OPERATING PRECAUTIONS.
could fall backward.
WARNING: Improper operation of the lift truck may • When leaving truck, neutralize travel control. Fully
result in operator injury, or load and/or lift lower lifting mechanism and set brake. When leaving
truck damage. Observe the following truck unattended, turn off key switch and disconnect
precautions when operating the PTE 45 switch, remove key and disconnect battery.
lift truck.
2-3. BEFORE OPERATION
The following safety precautions must be adhered to
at all times. Table 2-1 covers important inspection points on the
PTE 45 lift truck which should be checked prior to
• Do not operate this truck unless you have been
operation. Depending on use, some trucks may
trained and authorized to do so and have read all
require additional checks.
warnings and instructions in this manual and on the
truck. Figure 2-1 shows a sample format for a Operator
Checklist, which can be modified as necessary to fit
• All warnings and instructions must be read and
your operation.
understood before using the equipment.
• Equipment must be inspected by a qualified person WARNING: Periodic maintenance of this truck by a
on a regular basis. QUALIFIED TECHNICIAN is required.
• Do not operate this truck until you have checked its CAUTION: A QUALIFIED SERVICE TECHNICIAN
condition. Give special attention to Tires, Horn, Bat- should check the truck monthly for
teries, Controller, Lift System, Brakes, Steering proper lubrication, proper fluid levels,
Mechanism, Guards and Safety Devices brake maintenance, motor maintenance
• Operate truck only from designated operation posi- and other areas specified in the SEC-
tion. Wear foot protection. Do not carry passengers. TION 3.
• Observe applicable traffic regulations. Yield right of WARNING: If the truck is found to be unsafe and in
way to pedestrians. Slow down and sound horn at need of repair, or contributes to an
cross aisles and wherever vision is obstructed. unsafe condition, report it immediately to
the designated authority. Do not operate
• Start, stop, travel, steer and brake smoothly. Slow it until it has been restored to a safe
down for turns and on uneven or slippery surfaces operating condition. Do not make any
that could cause truck to slide or overturn. Use spe- unauthorized repairs or adjustments. All
cial care when traveling without load as the risk of service must be performed by a qualified
overturn may be greater. maintenance technician.
• Always look in direction of travel. Keep a clear view,
and when load interferes with visibility, travel with
load or lifting mechanism trailing.
901361 2-1
Table 2-1 Operator Checks
ITEM PROCEDURE ITEM PROCEDURE

Transmission and Check for signs of fluid leakage. Wheels Check drive wheel for cracks or
hydraulic sys- damage. Move truck to check
tems. load for freedom of rotation.
Forks Check for cracks and damage. Hydraulic Check operation of lift and lower
Guards and load Check that safety guards are in controls to their maximum positions.
backrest place, properly secured and not Brakes Check that brakes actuate when
damaged. steering arm is raised to upright
Safety signs Check that warning labels, position, and when lowered to
nameplate, etc., are in good horizontal position.
condition and legible. Deadman/ Check that steering arm raises to
Horn Check that horn sounds when Parking brake upright position when released
operated. and brake applies.
Steering Check for binding or looseness in Battery Check that battery can be
steering arm when steering. disconnect disconnected and recon-
nected. Check for connector
Travel controls Check that speed controls on
damage.
control head operate in all
speed ranges in forward and Battery charge Check that battery indicator is on
reverse and that belly button “1”.
switch functions.
2-2 901361
Electric Truck
Big Joe Manufacturing Company Daily Operator Check-Off List
Date Operator
Truck No. Model No.
Dept. Shift
Hour Meter
Reading Drive Hoist
Check O.K. ( ) Need Maintenance

Tires
Load Wheels
Horn
Lift Lower Control
Attachment Operation
Forward & Reverse Controls
Steering
Brakes
Hydraulic Leaks, Cylinders,
Valves, Hoses, Etc.
R6479
Figure 2-1 Sample of Operator Check List
901361 2-3
2-4. GENERAL CONTROL OPERATION.
The speed control (See Figure 2-2) located on each
side of the control head provides fingertip control for
driving the truck. Rotate the control in the direction you
want to travel. The farther you rotate the control from
the neutral position, the faster the truck will travel.
R6454
Figure 2-4. Brake Actuation
2-5. DRIVING AND STOPPING PROCEDURES.

1. Turn on the key switch and the disconnect switch.
Grasp the grips of the steering head so that the
R6453 speed control can be comfortably operated by
Figure 2-2. Forward/Reverse Control either thumb.
2. Lower the steering arm to a comfortable position
The pushbutton switches (See Figure 2-3), located on
above horizontal to disengage the brake and to
the front of the control head activate the lift-lower con-
energize the electrical circuits. If the truck is not
trols and the horn.
moved, the electrical circuits will time out and will
deenergize. See Figure 2-4.
3. To move forward (with load in front), slowly press
the speed control forward. See Figure 2-2. Press
the forward speed control farther to increase
speed.
4. To slow down or stop, release the speed control
and lower or raise the steering arm to the horizon-
tal or vertical position. See Figure 2-4. In those
positions, the brake engages, slowing or stopping
the truck.
5. Procedures for movement in reverse are the
same as in the forward direction except slowly
press the speed control backward. See Figure 2-
2.
R6452
Figure 2-3. Pushbutton Switches 2-6. BELLY-BUTTON SWITCH.
The brake is fully applied by lowering or raising the The belly-button switch (Figure 2-5) minimizes the
steering arm. (See Figure 2-4) All traction control possibility of the driver being pinned by the steering
power is shut off when the brake is engaged. When arm while driving the lift truck in slow speed. If the
the steering arm is in the upright position, the brake switch presses against the operator while the lift truck
acts as a parking brake. Deadman braking occurs is being driven toward the operator, the switch
when the handle is released and spring action raises changes the direction of the lift truck.
steering arm to the upright position.
2-4 901361
2-8. LIFT AND LOWER CONTROLS.
Lift/Lower Control buttons are located on the steering
control head. (Figure 2-3)
To lift forks, push in LIFT button and hold until forks
reach desired height. To lower forks, push in LOWER
button and hold until forks descend to desired height.
2-9. LOADING AND UNLOADING.

1. Move truck to location where load is to be picked
up.
2. Move the truck into position so forks are within
pallet or skid, and the load is centered over the
forks and as far back as possible.
R6455 3. Raise forks to lift load.
Figure 2-5. Belly-Button Switch 4. Drive to area where load is to be placed.
5. Move truck to align load with its new position.
2-7. STEERING ARM RETURN SPRING.
6. Lower the load until it rests squarely in place and
The steering arm return spring automatically raises the the forks are free.
steering arm to the upright position when the steering
7. Slowly move the truck out from under the load.
arm is released. If the steering arm does not return
fully, the steering arm return spring requires replace-
2-10.PARKING.
ment. Return truck to maintenance for repair.
When finished with moving loads, drive truck to its
maintenance or storage area. Turn off the disconnect
switch and the key switch. Charge batteries as neces-
sary. Refer to battery care instructions, SECTION 3.
901361 2-5
NOTES
2-6 901361
SECTION 3
PLANNED MAINTENANCE
3-1. GENERAL. Ultra-deep discharging of brand new batteries

Planned maintenance consists of periodic visual and should be avoided for at least 15 cycles. To dramat-
operational checks, parts inspection, lubrication, and ically extend battery life, ultra-deep discharge should
scheduled maintenance designed to prevent or dis- be avoided. The shallower the average discharge, the
cover malfunctions and defective parts. The operator longer the battery life.
performs the checks in SECTION 2, and refers any Charge the battery as described in paragraph 3-4.
required servicing to a qualified maintenance techni-
cian who performs the scheduled maintenance and 3-4. CHARGING BATTERIES
any required servicing.
Charging requirements will vary depending on depth of
discharge and temperature. Follow safety rules when
3-2. MONTHLY AND QUARTERLY CHECKS. placing a battery on charge.
Table 3-1 is a monthly and quarterly inspection and
Proceed as follows:
service chart based on normal usage of equipment
eight hours per day, five days per week. If the lift truck 1. Park truck at charging station with carriage low-
is used in excess of forty hours per week, the fre- ered and key switch and disconnect switch off.
quency of inspection and service should be increased 2. Check the condition of the AC cord, the battery
accordingly. These procedures must be performed by connector and battery cables. If there are any cuts
a qualified service technician or your Big Joe service in the cable, any exposed wires, loose plugs or
representative. connectors, DO NOT attempt to charge the bat-
teries. Contact appropriate personnel for repairs
3-3. BATTERY CARE. to be made.
These batteries are maintenance-free. Any attempt to
open the battery will void the warranty.
Table 3-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check condition of drive motor brushes and springs (Paragraph 10-5.1.).
Monthly Check mechanical brake for proper operation.
Monthly Check load wheels for wear. A poly load wheel must be replace if worn to within 1/16 inch of
hub. Check for separation from hub.
Monthly Check drive wheel for wear. A poly drive wheel must be replace if worn to within 1 inch of
hub. Check for separation from hub.
Monthly Check entry and exit wheels for wear or damage.
Monthly Inspect wiring for loose connections and damaged insulation.
Monthly Inspect contactors for proper operation.
Monthly Check deadman brake switch for proper operation.
Quarterly Check lift cylinder for leakage.
Quarterly Check for excessive jerking of steering arm when stopping or starting.
Semi-annually Check brake shoes for wear.
901361 3-1
3. Disconnect the batteries from the truck and con- are discharged, all four red LEDs will be on
nect the batteries to the charger. Make sure con- indicating maximum 25A charge current. As
nectors are mated properly. the batteries charge the current drops and
4. Connect the AC cord to the truck and then plug the LEDs go OFF as the current drops to
into the appropriate power supply. 20A, 15A, 10A and 5A respectively.
5. The battery charger is fully automatic and will 3-4.1. Removing Batteries from Charger
cycle automatically (depending on amount of
1. The Green “READY“ LED stays on until the
charge needed). Charge status can be observed
charger is unplugged from AC outlet.
as follows (Refer to Figure 3-1):
2. Disconnect AC plug from the power supply and
a. Three LED’s indicate charger status. At start then remove it from the truck.
of charge the RED (Charge) LED will be ON
indicating the batteries are connected and 3. Disconnect the batteries from the charger and
charging. After the batteries charge to connect the batteries to the truck. Make sure con-
approximately 80% the Yellow LED comes nectors are mated properly.
ON. After a time (1 hour minimum) the Green
LED comes ON indicating battery ready.
NOTE: The battery charger includes an override

timer which terminates the charge if the cycle
does not complete after 18 hours of charging.
This time-out condition is indicated by the
green LED flashing off and on, and it indi-
cates a fault condition which should be inves-
tigated. This will occur if the charger cannot
raise the battery voltage to the preset voltage
limit. Possible causes indicate a battery fault,
a charger fault, low AC power supply voltage,
or excessive discharge. The override timer
can be reset by switching the AC power to the
charger off. R6114
b. The next four red LED’s indicate current flow. Figure 3-1 Charge Indicator
Normally at start of charge, if the batteries
3-2 901361
3-5. LUBRICATION. Table 3-2 Recommended Lubricants
(See Table 3-3 for Application)
Refer to Table 3-2 for the recommended types of
grease and oil. Table 3-3 in conjunction with Figure 3-2 No. 1 Transmission oil—EP SAE 80W-90,
identifies the items requiring lubrication. Part Number 055780
Transmission oil—EP SAE 10W-30,
Part Number 055790 (Note)
No. 2 Grease—Lithium base, general purpose.

Part Number 055750
No. 3 Hydraulic oil-Heavy duty with a viscosity of

150 SUS foam suppressing agent and
rust and oxidation inhibitors
Part Number 055779
Hydraulic oil-Heavy duty with a viscosity of
100 SUS foam suppressing agent and
rust and oxidation inhibitors
No. 4 SAE 30 or 40 Engine lubricating oil

NOTE: USED ON COLD CONDITIONED TRUCKS
901361 3-3
R6480
Figure 3-2 Lubrication Diagram

Table 3-3 Lubrication Chart
FIG 3-2 LOCATION METHOD OF TYPE APPLICATION
INDEX APPLICATION (Table OF
NO. 3-3) LUBRICANT
1 Transmission Can No. 1 Fill to Hex plug (Fill level plug)
Capacity 2 pints level.
2 Steering arm pivot Can No. 4 1 or 2 drops each time serviced.
3 Pivot Tube Fitting Gun No. 2 Pressure lubricate.
4 Hydraulic System Can No. 3 With lift carriage fully lowered, fill
Capacity-6 quarts reservoir with hydraulic oil to 1
inch below opening.
5 Caster Fittings Gun No. 2 Pressure lubricate.
6 Lift Linkage Fittings* Gun No. 2 Pressure lubricate.
* Raise lift carriage to gain access to grease fittings.
3-4 901361
SECTION 4
TROUBLESHOOTING
4-1. GENERAL With Braking: Trouble With Lifting Or Lowering, and

Table 4-1 services as a guide to determine possible Miscellaneous malfunctions. Refer to electrical wiring
causes of trouble. The table is divided into five main schematic (Figure 4-6) as a supplement to the trouble-
categories: Truck Dead: Trouble With Travel: Trouble shooting chart or when tracing an electrical circuit.
Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TRUCK DEAD
Truck will not run nor will lift sys- a. Fuse (1, Figure 4-3) blown. Check fuse and replace if neces-
tem operate. sary.
b. Battery dead or disconnected. Check battery quick-disconnect
plug and check battery voltage.
c. Keyswitch (9, Figure 12-8) or Bypass keyswitch to determine if it
disconnect switch (10) defective. is malfunctioning. Then bypass
disconnect switch to determine if
it is malfunctioning.
d. Defective wiring. Check for open circuit. Repair as
required.
TROUBLE WITH TRAVEL
Truck does not run forward or a. Check all wiring. A loose con- Tighten all loose connections
reverse. All other functions oper- nection may be the cause of before further troubleshooting.
ate normally. malfunction.
b. Defective deadman switch (10, Check and replace switch if defec-
Figure 12-5). tive.
c. Defective main contactor (6, Check for proper operation and
Figure 4-3). replace if necessary.
d. Defective potentiometer (14, Check and replace potentiometer
Figure 12-3). if defective.
e. Transistor control fault may Move control arm up into the neu-
need to be reset. tral position to reset.
Truck runs forward but not in Defective reverse switch (6, Fig- Check for proper operation of
reverse. ure 12-3) in control head. reverse switch with steering arm
in operating position and replace
if necessary.
Truck runs reverse but not in for- Defective forward switch (6, Fig- Check for proper operation of
ward. ure 12-3) in control head. reverse switch with steering arm
in operating position and replace
if necessary.
Truck runs forward and in reverse Defective potentiometer (14, Fig- Check for variable resistance at
at lower speeds; will not run at ure 12-3) in control head. the potentiometer when direction
high speed. control is activated. If not noted,
replace potentiometer.
901361 4-1
Table 4-1 Troubleshooting Chart - Continued
TROUBLE WITH BRAKING
Truck does not slow with brake, or a. Defective deadman switch (10, Check deadman switch for conti-
brake does not engage. Figure 12-5). nuity. If none found when the
control arm is in the brake posi-
tion, replace switch.
b. Defective mechanical brake. Adjust brake or replace brake
shoes and drum as necessary.
TROUBLE WITH LIFTING OR
LOWERING
Oil sprays or flows from the top of Defective packing in lift cylinder. Replace lift cylinder.
the lift cylinder.
Squealing sounds when lifting a. Oil level too low. Add oil to reservoir.
forks. b. Lift linkage binding. Apply grease.
Forks do not lift to top. Oil level too low. Add oil to reservoir.
Weak, slow or uneven action of a. Defective pump or relief valve. Check pressure. Adjust as neces-
hydraulic system. sary.
b. Worn lift cylinder. Replace cylinder.
c. Load larger than capacity. Refer to I.D.platefor capacity.
d. Defective lift motor solenoid. Replace solenoid (3, Figure 4-3)
on electrical panel.
e. Battery charge low. Charge battery.
Forks do not lift, pump motor does 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,
operating pump motor. as well as the solenoid (3, Figure
4-3) on electrical panel. Replace.
Forks do not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir
and the oil lines to the lift cylin-
der, and repair as required. If
normal, check the hydraulic
pump, and relief valve. Repair, or
adjust.
Forks lift, but will not go down. Defect in hydraulic system Check lowering control switch (6,
Figure 12-3) and lowering sole-
noid on valve assembly (3, Fig-
ure 12-19). Replace as required.
Load will not hold a. Oil bypassing internally in con- Replace valve assembly (3, Fig-
trol valve ure 12-19).
b. Worn lift cylinder. Replace cylinder.
4-2 901361
TROUBLE WITH LIFTING OR
LOWERING - Continued
Platform does not lift to top. Pump a. Oil level too low. Add oil to reservoir.
motor runs. b. Load larger than capacity. Refer to nameplate on side of
mast for maximum load capacity.
c. Batteries need charging. Change batteries.
Forks creep downward under load Leak in hydraulic system, lift cylin- Check for leaking fitting in hydrau-
when in a raised position. der or lowering valve. lic line and repair as required.
Replace lift cylinder or valve
assembly (3, Figure 12-19).
MISCELLANEOUS
Steering arm does not return to a. Week return spring. Replace spring.
the upright position.
b. Binding. Check and free the binding item.
Verify that the cable has not
been damaged. Repair or
replace as needed.
Truck moves forward when arm is a. Belly-button switch defective. Check for short, and repair or
pulled down. replace as necessary.
b. Short in control head. Check wiring and repair as
required.
Steering arm jerks excessively Drive wheel worn. Replace drive wheel if worn to
starting or stopping the truck. within 3/8 inch of hub.
Drive motor is jerky. Motor commulator worn. Replace motor.
4-2. BATTERY CHARGER TROUBLESHOOTING 4-2.2. Thermistor

Refer to Figure 4-2 for part identification. Be sure the There is a temperature sensing thermistor plugged
batteries are connected to the charger and the AC into a 2-pin socket marked THERM on the PCB.
cord is connected to 120 VAC power supply. Check that this is firmly connected or the battery volt-
age control will not work properly.
4-2.1. Dip Switch Setting
The DIP switches (Figure 4-1) on the Printed Circuit 4-2.3. Circuit Breaker Testing
Board (PCB) must be set for Gel Cell Batteries. Check Using a multimeter set to measure 120 VAC, check
that switch 1 is ON and switch 2 is OFF. each side of the circuit breaker to ground. If 120 VAC
was not indicated on both sides, replace the circuit
breaker.
4-2.4. Power Transformer Testing

The two 0.250” tabs are the primary side of the trans-
former. The five #10 screw lugs are the secondary
side. Test the Transformer as follows:
R6120 1. Using a multimeter set to measure at least 120
VAC, verify that AC Power supply 120 VAC input
Figure 4-1. Dip Switch Settings
is present at the transformer primary terminals. If
120 VAC was not indicated, check the circuit
breaker and wiring.
901361 4-3
2. Using a multimeter set to measure at least 50 3. If the Green-Yellow-Red LED test sequence does
VAC, verify the transformer secondary terminals not show at power-up, or if it cycles constantly
as follows: Green-Yellow-Red, the PCB assembly should be
replaced.
a. Verify 25 VAC from blue wire to each white
wire. 4. If the Red or Yellow charging LED does not stay
ON after the test sequence, check that the batter-
b. Verify 50 VAC from the white wire to white
ies are connected to the charger.
wire.
5. Using a multimeter set to measure at least 30
c. If these voltages were not indicated, replace
VDC, verify DC Voltage from Black to Red wire is
the transformer.
as follows:
4-2.5. Circuit Board Testing a. If the Red charging LED is on and the Yellow
The circuit board has a built in diagnostic test at charging LED is off, voltage from black to red
power-up. wire should be at least 24 VDC.
1. Switch the AC supply OFF and then ON, watching b. If the Red and Yellow charging LEDs are on,
the 3 upper LEDs on the PCB. The 3 LEDs should voltage should be 29 ±1 VDC.
light briefly in sequence Green-Yellow-Red when c. If there is no Voltage, check the wiring and
power is applied. This indicates the transformer is connections from the charger to the battery
OK and that power is getting to the PCB. terminals. Battery Voltage must be correct
2. If the battery DC is connected to the charger cor- polarity and more than 1 Volt to commence
rectly, the Red LED should come ON immediately charging.
after this test sequence.
R6483
Figure 4-2. Battery Charger Wiring Diagram
4-4 901361
4-3. TRANSISTOR CONTROLLER TROUBLE- The automatic fault detection system includes:
SHOOTING
• Contactor coil open / shorted driver
4-3.1. Fault Detection. • Contactor driver over-current / contactor coil
The controller provides diagnostics information to short
assist technicians in troubleshooting drive system • Contactor welded
problems. When a fault is detected, the appropriate
• Emergency reverse circuit check
fault code is signaled via the LED, externally visible on
the side of controller (See Figure 4-3 for LED location • M- output fault
on controller). The diagnostic codes flashed by the • Memory checks upon start-up
LED are listed in Table 4-3.
• Over-voltage cutback
If the fault is critical, the controller is automatically dis-
abled. Faults can be caused internally (e.g. shorted • Power supply out of range (internal)
transistors) or externally (e.g., wrench or hardware • Throttle fault
dropped across controller terminals).
• Under-voltage cutback
To recover from a fault, the F/R switch must be turned
• Watchdog (external and internal)
off and back on again. If the fault has been corrected,
the controller will turn back on.
R6478
Figure 4-3. Electrical Panel Parts
901361 4-5
4-3.2. Hand Held Programmer (Optional) 1. If a programmer is available, connect it to the pro-
grammer connector (Figure 4-4) on the controller.
A hand held programmer is available that is designed
specifically for use with the controller. It serves dual 2. Turn the lift truck key switch to the ON position.
functions of reading diagnostic data provided by the The programmer should "power up" with an initial
controller and adjusting certain performance values of display (2, Figure 4-5), and the controllers Status
the controller. The programmer (Part Number LED should begin steadily blinking a single flash.
005472-02) is available through your Big Joe dealer. If If neither happens, check for continuity in the key
you require dealer location information, contact Big switch circuit and controller ground.
Joe Manufacturing Co. phone number 847-298-9800. 3. If you are using a programmer, put it into the diag-
nostic mode by pressing the "Menu Navigation
4-3.3. Fault Recording.
Key" (1, Figure 4-5). Using the Navigation key,
Fault events are recorded in the controller's memory. select the Faults menu. Display the Faults menu
However, multiple occurrences of the same fault are by pressing the Right side of the Navigation key.
recorded as one occurrence. Press the Right side of the Navigation key again
The fault event list can be loaded into the programmer to display the list of System Faults. The display
for readout. The Special Diagnostics mode provides should indicate "No Known Faults."
access to the controller's diagnostic history file. The
history file contains the entire fault event list created Release the brake by pulling down the steering
since the diagnostic history file was last cleared. The arm into the operating position. The controllers
standard Diagnostics mode provides information about LED should continue blinking a single flash and
only the currently active faults. the programmer should continue to indicate no
faults. If there is a problem, the LED will flash a
4-3.4. Fault Recovery. diagnostic code and the programmer will display a
diagnostic message. If you are conducting the
Almost all faults require a cycling of the KSl (Key
checkout without a programmer, look up the LED
Switch Input) or brake input to reset the controller and
diagnostic code in Table 4-3.
enable operation. Refer to Table 4-4 for fault clearance
requirements. When the problem has been corrected, it may be
necessary to cycle the brake in order to clear the
4-3.5. General Checkout. fault code.
Carefully complete the following checkout procedure. 4. With the brake released, select a direction and
If you find a problem during the checkout, refer to operate the throttle. The motor should begin to
paragraph 4-3.7. for further information. turn in the selected direction. If it does not, verify
The checkout can be conducted with or without the the wiring to the forward/reverse switches and
handheld programmer (See Paragraph 4-3.2.). How- motor. The motor should run proportionally faster
ever, the checkout procedure is easier with a program- with increasing throttle. If not, refer to Paragraph
mer. To evaluate the system without a programmer, 4-3.7.
observe the LED and note the flashing pattern and
refer to Table 4-3 for the code description.
CAUTION: Put the vehicle up on blocks to get the

drive wheel off the ground before begin-
ning these tests.
Turn the keyswitch off and make sure the

brake is applied, the throttle is in neutral,
and the forward/reverse switches are
open.
R6491
Do not stand, or allow anyone else to
stand directly in front of or behind the
vehicle during the tests. Figure 4-4. Controller Terminals
4-6 901361
4-3.6. Adjustment
2
To change a parameter (Table 4-2) using the program-
mer, use the Navigation key (1, Figure 4-5) to select
the "PROGRAM" menu. Press the Right key to display
a listing of program settings. Scroll down the Program
Listing until the desired parameter is highlighted on the
display. Press the Right key to display the settings for
1
+
the item selected. Press the Increase/Decrease key
("+" or "-") (3) until the desired value setting is
3 reached. The parameter is now set at the desired
-
value. All programming occurs in real time. That
means the parameter can be changed while the vehi-
cle is in operation.
Some parameters are dependant on other parame-
ters. When the programmer is being used to adjust a
I-7045 4 parameter and a limit is reached, the display will stop
Figure 4-5. Hand Held Programmer changing.
5. If you are using a programmer, put it into the test NOTE: Changing the value of the related parameter
mode by using the Navigation key (1) to select the may allow the original parameter to be
"Monitor" menu. Select the Monitor mode by adjusted further.
pressing the "Right" arrow on the Navigation key.
Table 4-2 Adjustment Settings
Press the Navigation key "Down" arrow to scroll
down to observe the status of the forward,
Function Setting
reverse, brake, emergency reverse, and mode
switches. Cycle each switch in turn, observing the Acceleration Rate (M1 thru M4) 2.0, 2.0,
programmer. Each input should show the correct 0.5, 0.5
state on the programmer. Braking Current Limit (M1 thru M4) 80, 80,
6. Check the controller's fault detection circuitry as 200, 200
described in Section 10-2.4. Deceleration Rate (M1 thru M4) 3.0, 3.0,
7. Take the vehicle off the blocks and drive it in a 5.0, 5.0
clear area. It should have smooth acceleration
and good top speed. 4-3.7. Diagnostics and Troubleshooting.
8. Test the plug braking of the vehicle. The vehicle The motor controller provides diagnostics information
should smoothly slow to a stop and reverse direc- to assist in troubleshooting drive system problems.
tion, with the audible plugging tone. The diagnostics information can be obtained in two
9. Verify that all options, such as high pedal disable ways:
(HPD), static return to off (SRO), and anti-tie- • Reading the appropriate display on the programmer
down, are as desired.
• Observing the fault codes issued by the Status LED.
10. Check to see whether the emergency reverse The Status LED is located on the side of the control-
(belly button) feature is working correctly. Verify ler. See Figure 4-3 for location of the LED on the
that the circuit is operational by momentarily dis- controller.
connecting one of the emergency reverse wires.
The vehicle should be disabled and a fault indi-
cated.
901361 4-7
4-3.7.1. LED Diagnostics 4-3.8. Programmer Diagnostics
During normal operation with no faults present, the With a programmer, diagnostics and troubleshooting is
Status LED flashes a single flash at approximately 1 more direct than with the LED alone. The programmer
flash/second. If the controller detects a fault, a 2-digit presents complete diagnostic information in plain lan-
fault identification code is flashed continuously until guage - no code to decipher. Faults are displayed in
the fault is corrected. For example, three flashes fol- the Diagnostic Menu, and the status of the controller
lowed by two flashes is code "3,2" appears in the LED inputs/outputs is displayed in the Test Menu.
code table as:
The following 4-step process is generally used for
000 00 000 00 000 00 diagnosing and troubleshooting an inoperative vehicle
using the programmer:
(3,2) (3,2) (3,2)
1. Visually inspect the vehicle for obvious problems:
The codes are listed in Table 4-3. The "0" 's in Table
4-3 indicate an illuminated LED. For suggestions 2. Diagnose the problem:
about possible causes of the various faults, refer to 3. Test the circuitry with the programmer:
Table 4-4 Troubleshooting Chart.
4. Correct the problem.
Operational faults, such as an over-temperature situa- Repeat the last three steps as necessary until the
tion, are cleared as soon as the operation is brought vehicle is operational.
within range. Non-operational faults, such as a throttle
fault, usually requires the brake or key switch to be Refer to the Table 4-4 for suggestions covering a
cycled after the problem is remedied. wide range of possible faults.
Table 4-3 LED Codes
LED Code Explanation

LED Off Not illuminated No power or defective controller
Solid On Always on Defective controller
Single Flash 0 Controller operational, no faults
1-2 0 00 Hardware fail-safe error
1-3 0 000 M- fault or motor output short
1-4 0 0000 Sequencing fault (SRO)
2-1 00 0 Throttle wiper high
2-2 00 00 Emergency reverse circuit check fault (BB wiring)
2-3 00 000 High-pedal-disable fault (HPD) or expired timer
2-4 00 0000 Throttle wiper low
3-1 000 0 Contactor driver over current or field winding short
3-2 000 00 Welded main contactor
3-3 000 000 Field winding open
3-4 000 0000 Missing contactor
4-1 0000 0 Low battery voltage
4-2 0000 00 Overvoltage
4-3 0000 000 Thermal cutback, due to over/under temp
4-4 0000 0000 anti-tiedown fault, or overheated motor
NOTE: Only one fault is indicated at a time and faults are not queued up.
4-8 901361
Table 4-4 Troubleshooting Chart
LED PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE
CODE LCD DISPLAY
0,1 NO KNOWN FAULTS
1,1 CURRENT SHUNT 1. Abnormal vehicle operation causing high current Cycle KSI. If problem persists, replace controller.
FAULT spikes.
2. Current sensor out of range.
3. Controller failure.
1,2 HW FAILSAFE 1. Noisy environment. Cycle KSI. If problem persists, replace controller.
2. Self-test or watchfault.
1,3 M- SHORTED 1. Internal or external short of M- to B-. Check wiring; cycle KSI. If problem persists,
replace controller.
2. Incorrect motor wiring.
1,4 SRO 1. Improper sequence of KSI, brake, interlock, and Follow proper sequence; adjust throttle if
direction inputs. necessary; adjust programmable parameters
if necessary.
2. Interlock or direction switch circuit open.
3. Sequencing delay too short.
4. Wrong SRO or throttle type selected.
5. Misadjusted throttle pot.
2,1 THROTTLE WIPER HI 1. Throttle input wire open or shorted to B+. When Throttle Wiper High input returns to valid
range.
2. Defective throttle pot.
3. Wrong throttle type selected.
2,2 EMR REV WIRING 1. Emergency reverse wire or check wire open. Re-apply emergency reverse or cycle interlock.
2,3 HPD 1. Improper sequence of KSI, interlock, and throttle Follow proper sequence; adjust throttle if
inputs necessary; adjust programmable parameters
2. Misadjusted throttle pot. if necessary.
3. Sequencing delay too short.

4. Wrong HPD or throttle type selected.
5. Misadjusted throttle pot.
SRVC TOTAL 1. Total maintenance timer expired. Reset with programmer.
SRVC TRAC 1. Traction maintenance timer expired. Reset with programmer.
TOTAL DISABLED 1. Total disable timer expired. Reset with programmer.
TRAC DISABLED 1. Traction disable timer expired. Reset with programmer.
2,4 THROTTLE WIPER LO 1. Throttle pot wire open or shorted to B+. When Throttle Wiper Low input returns to valid
range.
2. Wrong throttle type selected.
3. Defective throttle pot.
3,1 FIELD SHORT 1. Main contactor soil shorted. Check contactor soil and field winding; cycle KSI.
2. Field winding shorted to B+ or B-.
3. Field resistance too low.
3,2 MAIN CONT WELDED 1. Main contactor stuck closed. Check wiring and contactor; cycle KSI.
2. Main contactor driver shorted.
3,3 FIELD OPEN 1. Field winding connection open. Check wiring and cycle KSI.
2. Field winding open.
3,4 MISSING CONTACTOR 1. Main contactor coil open. Check wiring and cycle KSI.
2. Main contactor missing.
3.Wire to main contactor open.
901361 4-9
4,1 LOW BATTERY VOLT- 1. Battery voltage < undervoltage cutback. When voltage rises above undervoltage cutoff
AGE point.
2. Corroded battery terminal.
3. Loose battery or controller terminal.
4,2 OVERVOLTAGE 1. Battery voltage > overvoltage shutdown limit. When voltage falls below overvoltage cutoff point.
4,3 THERMAL CUTBACK 1. Temperature >85°C or <-25°C. Clears when heatsink temperature returns to within
acceptable range.
2. Excessive load on vehicle.
3. Improper mounting of controller.
4,4 ANTI-TIEDOWN 1. Mode switches shorted to B+. Release Mode Select 1.
2. Mode Select 1:”tied down” to select Mode 2 or
Mode 4 permanently.
MOTOR HOT 1. Field resistance > motor hot setpoint. When resistance < setpoint.
MOTOR WARM 1. Field resistance > motor warm setpoint. When resistance < setpoint.
4-10 901361
NOTES
901361 4-11
R6490A
Figure 4-6 Wiring Diagram (Sheet 1)
4-12 901361
R6490B
Figure 4-6 Wiring Diagram (Sheet 1)
901361 4-13
NOTES
4-14 901361
SECTION 5
STEERING ARM, CONTROL HEAD AND PIVOT SERIVCE
5-1. CONTROL HEAD 13. Install the control head as described in paragraph
5-1.6.
5-1.1. Control Head Removal.
1. Turn off the key switch (9, Figure 12-8), discon- 5-1.3. Lift, Lower and Horn Switch Replacement.
nect switch (10) and disconnect the batteries. 1. Remove the control head as described in para-
2. Remove the six outer screws (12, Figure 5-1) and graph 5-1.1.
lift off cover (18). 2. Place the control head on a clean work bench.
NOTE: The seventh inner screw (14) and nut (13) 3. Trace the leads of the defective switch down to
secure support plate (22) to cover (18). the control head connector and remove the leads
from the connector.
NOTE: When removing the control head in the fol-
lowing step, be sure to hold it in place until NOTE: When screw (14, Figure 5-1) and nut (22) are
the control cable is disconnected. removed, springs (12) will fall out.
3. Working inside the control head, remove two 4. Use a small clamp to hold plate (22) and cover
screws (3, Figure 5-2) and two washers (4), being (18) together. Remove screw (14) and nut (23).
careful not to drop control head (1). Slowly remove the clamp and separate plate (22)
from cover (18) being careful not to loose springs
4. Lift up control head (1) and unplug the electrical (12).
connector.
5. Remove the switch assembly (9, 15 or 19) with
5-1.2. Belly-Button Switch Replacement. the defective switch.
1. Remove the control head as described in para- 6. Pick out potting compound and remove switch
graph 5-1.1. from button.
2. Place the control head on a clean work bench. 7. Position new switch in button and secure in place
with potting compound.
3. Trace the belly-button switch leads down to the
control head connector and remove the leads 8. Place switch assemblies (9, 15 and 19) with
from the connector. springs (12) in position cover (18).
4. Remove two screws (7, Figure 5-1) and two screw 9. Place plate (22) into position and temporary
(8). secure with a clamp. Install nut (23) and screw
(14). Then remove the clamp.
5. Lift switch assembly (1) with mounting bracket (6)
out of the control head. 10. Check buttons for proper operation.
6. Remove switch assembly (1) from mounting 11. Install the switch leads in the control head con-
bracket (6) being careful not to loose springs (4). nector.
7. Pick out potting compound and remove switch (3) 12. Install the control head as described in paragraph
from button (1). 5-1.6.
8. Position new switch (3) in button (2) and secure in 5-1.4. Directional Switch Removal and Adjust-
place with potting compound. ment.
9. Install switch assembly (1) with springs (4) on 1. Remove the control head as described in para-
mounting bracket (6) and check for proper opera- graph 5-1.1.
tion.
2. Place the control head on a clean work bench.
10. Position switch assembly (1) with mounting
bracket (6) in the control head. 3. Remove two screws (11, Figure 5-3) and lift
mounting bracket (8) out of the control head.
11. Install two screws (7) and two screw (8).
4. Remove two nuts (10) and two washers (9) from
12. Install the switch leads in the control head con- two screws (5).
nector.
901361 5-1
5. Remove the two screws (5) with switches (6) and 9. Check that rollers on both switches (6) contact the
block (7). surface of cam (4) but do not engage the switches
6. Remove the switch leads from the control head in the neutral position. If required, loosen screw
connector. (11) and adjust position of bracket (8) to obtain
proper operation.
7. Position the new switches (6) and block (7) on
mounting bracket (8) and secure with two screws 10. Install the switch leads in the control head con-
(5), two washers (9) and two nuts (10). nector.
8. Position mounting bracket (8) in the control head 11. Install the control head as described in paragraph
and install two screws (11). 5-1.6.
R6461A
Figure 5-1. Control Head Switches
5-2 901361
R6460
Figure 5-2. Control Head and Steering Arm
901361 5-3
5-1.5. Potentiometer Removal Testing and Adjust- 8. Position mounting bracket (13) in the control head
ment. and install two screws (11).
1. Remove the control head as described in para- 9. Set an ohmmeter to the RX1K (1000) scale and
graph 5-1.1. connect across the potentiometer leads.
2. Place the control head on a clean work bench. 10. Slowly press the control knob (18) in the forward
direction until a click indicating forward switch clo-
3. Remove two screws (11, Figure 5-3) and lift
sure is heard and record the ohmmeter reading.
mounting bracket (13) out of the control head.
11. Repeat step 10. while pressing control lever in
4. Remove gear (12) from potentiometer (14).
reverse direction. Meter readings should be the
5. Remove the potentiometer mounting nut and same as for the forward direction (±200 ohms). If
remove potentiometer (14) from mounting bracket meter readings are not the same, adjust position
(13). of bracket (13) as necessary to obtain the same
6. Remove the potentiometer leads from the control values. Adjust the potentiometer again if neces-
head connector. sary.
7. Position the new potentiometer (14) on mounting 12. Install the potentiometer leads in the control head
bracket (13) and secure with potentiometer connector.
mounting nut. 13. Install the control head as described in paragraph
5-1.6.
R6462
Figure 5-3 Drive Controls
5-4 901361
5-1.6. Control Head Installation. 8. While standing on the steering arm, pull up on the
pipe and remove the pin installed in step 2. Then
1. Position control head (1, Figure 5-2) on arm (7)
slowly let chain (15) retract back into the steering
and plug in the electrical connector.
arm.
2. Working inside the control head, install two
screws (3) and two washers (4). 9. Working from the control head end, remove the
spring (19) from steering arm (7).
3. Install cover (18, Figure 5-1) and secure with six
10. Remove tube (19) from spring (19).
screws (13)
11. Inspect chain (15) and replace if necessary.
4. Reconnect the batteries and turn on the keyswitch
(9, Figure 12-8) and switch (10). 12. Inspect sheave (8) and replace if necessary.
13. Reassemble in reverse order.
5-2. STEERING ARM
5-3. BATTERY INDICATOR REPLACEMENT.
5-2.1. Return Spring Replacement.
1. Turn off the key switch (9, Figure 12-8), discon-
The steering arm return spring (18, Figure 5-2) is
nect switch (10) and disconnect the batteries.
replaced while the steering arm (7) is in the upright
position. 2. Remove four screws (2) and cover (4).
1. Remove the control head as described in para- 3. Tag and disconnect electrical leads from indicator
graph 5-1.1. (11).
2. Pull the steering arm (7) down to and insert a pin 4. Remove two knurled nuts and U-bracket, part of
through chain (15) to prevent it from retracting battery indicator (11), to release and remove the
back into the steering arm. indicator.
3. Slightly raise the steering arm (7) and remove the NOTE: Replacement indicator will be furnished with
master link (16) securing chain (15) to screw (14). nuts and U-bracket. The original U-bracket
4. Drive out pin (12) and remove cam (11). may be reused, if not damaged.
5. Remove the electrical cable from steering arm (7) 5. Install battery discharge indicator (11) and secure
while removing the steering arm. with supplied U-bracket and nuts. If required, trim
6. Lay steering arm (7) flat on the ground with chain the U-bracket legs to proper length.
(15) facing up. 6. Reconnect electrical leads, as noted during
7. Insert a wire through chain (15) and secure to a removal.
pipe that can be used as a handle. 7. Reinstall the cover (4) and screws (2).
CAUTION: The following step requires two people. 8. Reconnect the batteries and turn on the keyswitch
One to pull on the handle to stretch the (9) and switch (10).
spring. The second to remove the pin
installed in step 2.
901361 5-5
NOTES
5-6 901361
SECTION 6
BRAKE SERVICING
6-1. BRAKES. 18. Install cover (4) and screws (2).
6-1.1. Adjustment. 6-1.2. Brake Shoe Replacement.

1. Turn off the key switch (9, Figure 12-8), discon- 1. Turn off the key switch (9, Figure 12-8), discon-
nect switch (10) and disconnect the batteries. nect switch (10) and disconnect the batteries.
2. Remove four screws (2) and cover (4). 2. Remove four screws (2) and cover (4).
3. Remove four screws (5) and cover (6). 3. Remove four screws (5) and cover (6).
4. Remove four screws (19, Figure 6-1) and cover 4. Remove four screws (19, Figure 6-1) and cover
(18) from transmission (8). (18) from transmission (8).
5. Using a strap wrench to hold drum (17), remove 5. Using a strap wrench to hold drum (17), remove
nut (9). nut (9).
6. Remove drum (17) and key (10) from drive motor 6. Remove drum (17) and key (10) from drive motor
(15). (15).
7. Remove link (25) and free yoke (26) from the 7. Remove link (25) and free yoke (26) from the
lever of brake assembly (16). lever of brake assembly (16).
8. Remove clip (7, Figure 6-2) from cam (4). 8. Remove springs (1, Figure 6-2) from shoes (2)
9. Move lever (6) on teeth of cam (4) to adjust the and remove the shoes from plate (5).
brakes. 9. Position new shoes (2) on plate (5) and install
10. Reinstall clip (7) on cam (4). springs (1).
11. Attach yoke (26, Figure 6-1) to the lever of brake 10. Attach yoke (26, Figure 6-1) to the lever of brake
assembly (16) and secure with link (25). assembly (16) and secure with link (25).
12. Install key (10) and drum (17) on drive motor (15). 11. Install key (10) and drum (17) on drive motor (15).
13. Using a strap wrench to hold drum (17), install 12. Using a strap wrench to hold drum (17), install
nut (9). nut (9).
14. Reconnect the batteries and turn on the keyswitch 13. Reconnect the batteries and turn on the keyswitch
(9, Figure 12-8) and switch (10). (9, Figure 12-8) and switch (10).
15. Check if the brake works normally. If not, repeat 14. Check if the brake works normally. If not, adjust
steps 5. though 13. the brake as described in paragraph 6-1.1.
16. Install cover (18, Figure 6-1) on transmission (8) 15. Install cover (18, Figure 6-1) on transmission (8)
and secure with four screws (19). and secure with four screws (19).
17. Install cover (6, Figure 12-8) and screws (5). 16. Install cover (6, Figure 12-8) and screws (5).
17. Install cover (4) and screws (2).
901361 6-1
R6463
Figure 6-1 Drive Assembly
R6465
Figure 6-2 Brake Assembly
6-2 901361
SECTION 7
TRANSMISSION, DRIVE WHEEL, LOAD WHEEL, SKID BAR
AND ENTRY/EXIT ROLLER SERVICING
7-1. Drive Wheel. NOTE: Support the transmission assembly during

removal of the mounting hardware.
nect switch (10) and disconnect the batteries. 8. Remove nut (2, Figure 7-1) and washer (3).
2. Remove four screws (19) and cover (18). 9. Slowly lower the transmission out the bottom of
3. Loosen but do not remove nut (14, Figure 7-1). the frame.
4. Jack up the truck so the drive wheel is off the 10. If necessary, remove bearings (4 and 5) seal (6)
ground; then securely block the truck to prevent and ring (7).
movement. 11. Remove the drive wheel (13) from the transmis-
5. Remove the drive wheel (13) from the transmission by removing nut (14).
sion. 12. Install new transmission by reversing steps 1.
6. Install new drive wheel in reverse order of through 11. above.
removal.
7. Reconnect the batteries and turn on the keyswitch 7-3. Load Wheel.
(9, Figure 12-8) and switch (10). 7-3.1. Removal
7-2. Transmission. 1. Raise forks.

NOTE: The transmission does not have any user ser-
viceable parts. If the transmission is the
cause of travel problems, it will need to be 3. Block the drive wheel to prevent the truck from
replaced. rolling.
4. Jack up the forks to raise the load wheels off the
1. Remove the drive wheel as described in para- floor. Securely block the forks in the raised posi-
graph 7-1. tion by positioning supports under both fork tips.
2. Remove the brake as described in paragraph
6-1.2. NOTE: When pin (5, Figure 7-2) is removed, load
wheel assembly (6) will drop free.
3. Remove the motor as described in paragraph
10-5.2. 5. Remove screw (6) securing pin (5) and remove
4. Remove the control head as described in para- pin (5) and load wheel assembly (8).
graph 5-1.1. NOTE: Inspect the load wheel assembly. If the load
5. Remove the steering arm as described in para- wheel is worn within 1/8" of the metal sleeve,
graph 5-2. or is cracked or damaged, replace the entire
6. Remove all cables from the pivot tube of the load wheel and bearing assembly. Big Joe
transmission. recommends that both load wheel assem-
blies be replaced at the same time. This
7. Jack up the truck so the drive wheel is off the ensures level and safe operation of the lift
ground; then securely block the truck to prevent truck.
movement.
901361 7-1
R6463
7-2 901361
7-3.2. Repair 2. Install pin (5) and secure with screw (6).
1. Remove seals (1, Figure 7-2) and rings (2) from 3. Remove blocking from under the truck.
wheels (4). 4. Lower the forks.
2. Remove bearings (3) from wheels (4). 5. Reconnect the batteries and turn on the keyswitch
3. Inspect bearings (3) and replace if necessary. (9, Figure 12-8) and switch (10).
4. Inspect seals (1) and replace if necessary.
7-4. SKID BAR
5. Reassemble wheel in reverse of disassembly pro-
cedure. Skid bars are provided for additional stability. Installa-
tion of the skid bars are shown in Figure 12-10 and
7-3.3. Load Wheel Installation repair parts as shown in Figure 12-11.
1. Position load wheel assembly (8, Figure 7-2) in
wheel fork (9).
R6481
Figure 7-2. Wheel Assembly
901361 7-3
7-5. ENTRY AND EXIT ROLLERS 5. Remove screws (2, Figure 7-3), bracket (4) and
Entry and exit rollers provide smoother transition in spacer (3) from the fork tip.
and out of the pallets. 6. Remove cotter pin (6) and washer (5).
7. Remove pin (7) and roller (5) from bracket (4).
7-5.1. Entry Roller Replacement
8. Position new roller (4) in bracket (1) and insert pin
1. Raise forks.
(7).
9. Install washer (1) and cotter pin (6).
10. Position bracket (4) and spacer (3) in the fork tip
3. Block the drive wheel to prevent the truck from and secure with screws (2).
rolling.
11. Remove blocking from under the truck.
floor. Securely block the forks in the raised posi- 12. Lower the forks.
tion by positioning supports under both fork tips. 13. Reconnect the batteries and turn on the keyswitch
(9, Figure 12-8) and switch (10).
R6532
Figure 7-3 Entry Rollers
7-4 901361
7-5.2. Exit Roller Replacement
1. Raise forks.
3. Block the drive wheel to prevent the truck from
rolling.
floor. Securely block the forks in the raised posi-
tion by positioning supports under both fork tips.
5. Remove screw (10, Figure 12-10). Support rod
(17) and remove pin (11).
6. Lower the lift linkage to the ground.
7. Remove screws (12, Figure 7-4 or Figure 7-5) and
rollers (4).
R6534
8. If necessary, replace bracket (1) as follows:
a. Remove screws (3), washers (2) and bracket Figure 7-4 Left Exit Rollers
(1) from the fork.
b. Note the position of screws (6 and 7) and
remove the screws from the bracket.
c. Install screws (6 and 7) in the new bracket
until at the position noted during removal.
d. Position the bracket in the fork and secure
washers (2) and screws (3).
9. Install rollers (4) and screws (5).
10. Raise the lift linkage into position and install pin
(11, Figure 12-10) being sure to align the set
screw hole in the pin with the hole in the fork.
11. Install screw (10).
12. Remove blocking from under the truck.
13. Lower the forks.
14. Reconnect the batteries and turn on the keyswitch R6533
Figure 7-5 Right Exit Rollers
901361 7-5
NOTES
7-6 901361
SECTION 8
ELEVATION SYSTEM SERVICING
8-1. GENERAL. 7. Position fork (13) in the fork and install pin (11).
The elevation system includes the lift linkage, power Secure pin (11) with screw (10).
section and fork section. 8. Raise rod (17) into position and install pin (19)
through the frame. Secure Pin (19) with screw
8-2. Lift Linkage (18).
9. Position links (23) on carrier frame (27) and install
8-2.1. Removal
shaft (22). Secure with screw (10).
1. Lift complete truck to height sufficient to permit
10. Remove blocking and lower the truck to the
access to lift linkage under forks. Provide blocking
ground.
under carrier frame (27, Figure 8-1), the rear of
frame (5) and at tips of the forks. 11. Reconnect the batteries and turn on the keyswitch
nect switch (10) and disconnect the batteries. 8-3. Power Section and Fork Section
3. Remove screw (10, Figure 8-1) from carrier frame
(27) and drive out shaft (22). 8-3.1. Separating Power Section and Fork
Section.
4. Remove screw (18). Support rod (17) and remove
pin (19). Lower the end of rod (17) to the floor. 1. Support entire truck on blocking, providing sepa-
rate blocks so that frame (5, Figure 8-1) can be
5. Remove screw (10). Support rod (17) and remove
fully supported when carrier frame (27) is
pin (11).
removed.
6. Remove rod (17) with attached parts from under
the fork.
7. Remove screw (20) from link (23) and remove pin
(21) and links (23). 3. Remove four screws (2) and cover (4).
4. Remove the lift cylinder as described in para-
8. Remove bearings (16) from links (23).
graph 9-2.4.
9. Remove screw (15) from wheel fork (13) and
5. Remove the drive wheel as described in para-
remove pin (14) and wheel fork (13).
graph 7-1.
10. Remove bearings (16) from each end of rod (17).
11. Remove the load wheel from wheel fork as 6-1.
described in paragraph 7-3.1.
7. Remove the motor as described in paragraph
8-2.2. Reassembly 10-5.2.
1. Install the load wheel in wheel fork as described in 8. Remove the control head as described in para-
paragraph 7-3.3. graph 5-1.1.
2. Install bearing (16, Figure 8-1) in the ends of rod 9. Remove the transmission as described in para-
(17). graph 7-2.
3. Position wheel fork (13) on the end of rod (17) as 10. Attach a suitable hoist to carrier frame (27, Figure
shown. Secure by installing pin (14) through the 8-1).
lower hole in fork (13). Secure pin (14) with screw 11. Remove screw (10) from carrier frame (27) and
(15). remove shaft (22) on each side of carrier frame
4. Install bearings (16) in links (23). (27).
5. Position rod (17) between the upper hole in links 12. Remove screw (24) from each side of carrier
(23) as shown and install pin (21). Secure pin (21) frame (27) and remove the carrier frame.
with screw (20). 13. Remove screws (24) and links (25) from frame
6. Position rod (17) with attached parts under the (5).
fork. 14. Remove bearings (26) from links (25).
901361 8-1
8-3.2. Frame Repair. 4. Move links (23) into position on each side of car-
rier frame (27) and install shaft (22). Secure shaft
1. Removal of components mounted on frame (12,
with screw (10).
Figure 8-1) may be necessary to effect repairs/
welding, refer to table of contents for identification 5. Remove hoist from carrier frame (27).
of instructions on such components. 6. Install the transmission as described in paragraph
2. Inspect frame (5) for broken welds and weld as 7-2.
necessary. 7. Install the control head as described in paragraph
3. Replace frame (5) if forks have been bent 5-1.6.
severely. 8. Install the motor as described in paragraph
10-5.3.
8-3.3. Carrier Frame Repair.
9. Install the brake as described in paragraph
1. Repair of the carrier frame (27, Figure 8-1) is lim-
6-1.
ited to chasing damaged threads and welding of
any broken welds. 10. Install the drive wheel as described in paragraph
7-1.
8-3.4. Mating Power Section and Fork Section. 11. Install the lift cylinder as described in paragraph
1. Install bearings (26, Figure 8-1) in links (25). 9-2.4.
2. Attach links (25) to frame (5) with screws (24). 12. Install cover (6, Figure 12-8) and four screws (5).
3. With suitable hoist, carefully move carrier frame 13. Install cover (4) and four screws (2).
(27) into position and attach links (25) with screws 14. Reconnect the batteries and turn on the keyswitch
(24). (9) and switch (10).
15. Remove the blocking from under the truck.
R6469
Figure 8-1 Frame
8-2 901361
SECTION 9
HYDRAULIC SYSTEM SERVICING
9-1. LINES AND FITTINGS 4. Refer to Figure 9-1 and remove leaking line or fit-
ting and replace it with a new line or fitting.
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To 5. Remove elbow (11, Figure 9-2) from the hydraulic
ensure release of pressure, forks must reservoir. Check level of hydraulic oil. Hydraulic
be fully lowered and the batteries discon- oil must be one inch below opening. If required,
nected before performing any mainte- add hydraulic oil to bring to proper level. Use
nance on the hydraulic system. hydraulic oil listed in Table 3-2.
6. Reinstall elbow (11).
NOTE: Leaking hydraulic fittings may be remedied by
simply tightening fittings. If this does not rem- 7. Reconnect the batteries and turn on the keyswitch
edy the leak, the fittings or line must be (9, Figure 12-8) and switch (10).
replaced. 8. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
1. Lower forks fully.
9. Remove elbow (11, Figure 9-2) from the hydraulic
2. Turn off the key switch (9, Figure 12-8), discon- reservoir. Check level of hydraulic oil. Hydraulic
nect switch (10) and disconnect the batteries. oil must be one inch below opening. If required,
3. Remove four screws (2) and cover (4). add hydraulic oil to bring to proper level. Use
hydraulic oil listed in Table 3-2.
CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container 10. Reinstall elbow (11).
under the line or fitting before discon- 11. Install cover (4, Figure 12-8) and four screws (2).
necting.
R6466
Figure 9-1 Hydraulic System
901361 9-1
9-2. HYDRAULIC PUMP, MOTOR, AND RESER- 9-2.2. Disassembly and Reassembly
VOIR ASSY
1. Remove the hydraulic pump/motor assembly as
The hydraulic pump/motor assembly can be disas- described in paragraph 9-2.1.
sembled and repaired. However, a defective pump, 2. Remove four screws (10, Figure 9-2), washers (9)
valve or motor requires replacement of that compo- and reservoir (8).
nent.
3. Remove and discard O-ring (4).
WARNING: When forks are raised. pressure exists in 4. Remove two screws (6) and two screws (7).
the hydraulic system lines and fittings. To
ensure release of pressure, forks must 5. Separate pump (5), motor (1), sleeve (2) and
be fully lowered and the batteries discon- valve (3).
nected before performing any mainte- NOTE: Coat new O-ring (4) with hydraulic oil to pre-
nance on the hydraulic system. vent damage during reassembly.
9-2.1. Removal 6. Reassemble the hydraulic pump by reversing the
1. Lower forks fully. above procedure.
2. Turn off the key switch (9, Figure 12-8), discon- 9-2.3. Installation
1. Position the pump/motor assembly (9, Figure 9-1)
3. Remove four screws (2) and cover (4). in the compartment and secure with screws (8).
4. Remove the battery and charger assembly as 2. Reconnect hose (6) to pump/motor assembly (9).
3. Reconnect electrical leads and spike suppressor
5. Tag and disconnect electrical leads from the to solenoid (15, Figure 9-2).
motor.
4. Reconnect electrical leads to the motor.
6. Tag and disconnect electrical leads and spike
suppressor from the solenoid (15, Figure 9-2). 5. Fill hydraulic reservoir by removing elbow (11).
Use approved Big Joe hydraulic fluid.
NOTE: The reservoir and hose will be filled with 6. Reinstall elbow (11).
hydraulic oil. Place a container under the
pump assembly to catch any hydraulic oil. 7. Reinstall the battery and charger assembly as
7. Disconnect hose (3, Figure 9-1) from pump/motor 8. Reconnect the batteries and turn on the keyswitch
assembly (9). (9, Figure 12-8) and switch (10).
8. While supporting the pump/motor assembly (9), 9. Bleed air from the hydraulic system by repeatedly
remove screws (8). raising and lowering lift truck until action is
9. Remove the pump/motor assembly (9). smooth.
10. Refill the hydraulic reservoir.
11. Install cover (4) and four screws (2).
9-2 901361
R6467
Figure 9-2 Hydraulic Power Unit
901361 9-3
9-2.4. Lift Cylinder 9-2.5. Hydraulic Pressure Adjustment
NOTE: The lift cylinder does not have any user ser- The relief valve is factory set to open at the rated pres-
viceable parts. If the cylinder is defective, it sure setting for the pump (not to exceed 2,600 psi) and
will need to be replaced. rarely needs adjusting. If you suspect that the relief
valve is malfunctioning, perform the following proce-
9-2.4.1.Removal dures:
1. Lower forks fully. 1. Lower forks as far as they will go.
2. Turn off the key switch (9, Figure 12-8), discon- 2. Remove four screws (2, Figure 12-8) and cover
nect switch (10) and disconnect the batteries. (4).
3. Remove four screws (2) and cover (4). 3. Disconnect hose (3, Figure 9-1) from pump/motor
4. Ensure that hydraulic pressure has been relieved assembly (9) and connect a pressure gauge of
from the lift circuit. Disconnect the hydraulic line adequate range (0-3000 psi) in its place.
from the lift cylinder. 4. Activate pump motor and observe reading on
5. Disconnect hose (3, Figure 9-1) from cylinder (1) pressure gauge. If pressure reading is 2,600 psi,
and discard O-ring (2). the relief valve is functioning properly and does
not need adjustment. If pressure reading is not
6. Remove the four screw and two brackets securing 2,600 psi, proceed as follows to adjust relief
the cylinder to carrier frame (27, Figure 12-10). valve:
WARNING: Frame is heavy. Use care while securing CAUTION: Do not set pressure too high or hydraulic
and lifting in order to prevent injury. system may be damaged. Factory rec-
7. With suitable hoist, carefully raise frame (5) ommended setting of 2,600 psi should
slightly so the cylinder can be removed. be observed. Under no circumstances
should pressure be set above 2,600 psi,
9-2.4.2.Installation
5. Remove nut to gain access to adjusting bolt. With
1. Position the new cylinder (1, Figure 9-1) on carrier pump motor running, observe pressure gauge
frame (27, Figure 12-10). Then lower the frame and set pressure to 2,600 psi by turning adjusting
(5) onto the cylinder. bolt clockwise to increase pressure or counter-
2. Reconnect the hose (3, Figure 9-1) to cylinder (1) clockwise to decrease pressure.
with new O-ring (2). 6. Deactivate pump motor, disconnect pressure
3. Fill hydraulic reservoir by removing elbow (11, gauge, and reconnect hose (3, Figure 9-1).
Figure 9-2). Use approved Big Joe hydraulic fluid. 7. Fill hydraulic reservoir by removing elbow (11,
4. Reinstall elbow (11). Figure 9-2). Use approved Big Joe hydraulic fluid.
5. Reconnect the batteries and turn on the keyswitch 8. Reinstall elbow (11).
(9, Figure 12-8) and switch (10). 9. Bleed air from the hydraulic system by repeatedly
6. Bleed air from the hydraulic system by repeatedly raising and lowering lift truck until action is
raising and lowering lift truck until action is smooth.
smooth. 10. Refill the hydraulic reservoir.
7. Refill the hydraulic reservoir. 11. Install cover (4, Figure 12-8) and four screws (2).
8. Install cover (4) and four screws (2).
9-4 901361
SECTION 10
ELECTRICAL COMPONENTS
10-1.BATTERY AND CHARGER ASSEMBLY 10-1.4.Battery and Charger Assembly Installation
10-1.1.Battery and Charger Assembly Removal 1. Using a suitable hoist, slowly lower the battery
and charger assembly into position.
WARNING: Batteries available for the lift truck vary in 2. Secure the battery and charger assembly to the
weight. A suitable hoist and sling truck with the four screws
arrangement must be used to prevent
injury or battery damage. 3. Install cover (4, Figure 12-8) and four screws (2).
1. Turn off the key switch (9, Figure 12-8), discon- (9) and switch (10).
2. Remove four screws (2) and cover (4). 10-2.ELECTRICAL CONTROL PANEL
3. Remove the four screws securing the battery and
10-2.1.Maintenance
charger assembly to the truck.
4. Using a suitable hoist, slowly raise the battery and NOTE: Erratic operation of the truck may be caused
charger assembly up and out of the truck. by defective controller components. Before
removing the electrical panel, perform trou-
5. Set the assembly on suitable blocking. bleshooting procedures per SECTION 4, to
10-1.2.Battery Removal and Replacement determine corrective action to be taken.
1. Remove the battery and charger assembly as There are no user-serviceable parts inside the control-
described in paragraph 10-1. ler. No attempt should be made to open the controller.
Opening the controller may damage it and will void the
2. Disconnect the cable assemblies from the batter-
warranty.
ies (30).
3. Remove the batteries (30) from battery box (1). The controller is programmed at the factory specifi-
cally for the truck model on which it is equipped. It is
4. Reverse procedure for installation. important to replace the controller with the correct pre-
10-1.3. Battery Charger programmed unit to assure proper performance set-
tings intended for that particular truck. See Figure 12-
Refer to paragraph 4-2. for troubleshooting proce- 17 for the preprogrammed controller number.
dures. Refer to Figure 10-1 for disassembly and part
It is recommended that the controller exterior be
identification. Be sure the AC cord is connected to
cleaned periodically, and if a handheld programmer is
proper power supply.
available, this periodic cleaning provides a good
opportunity to check the controller’s diagnostic history
file. It is also recommended that the controller’s fault
detection circuitry be checked whenever the vehicle is
serviced.
901361 10-1
R6477
Figure 10-1 Battery and Charger Assembly - Two 12V Batteries
10-2 901361
R6489
Figure 10-2 Battery and Charger Assembly - Four 6V Batteries
901361 10-3
10-2.2.Cleaning Faults->Clear Fault History.
1. Turn off the key switch (9, Figure 12-8), discon- You will be asked to confirm your actions. Use the
nect switch (10) and disconnect the batteries. "plus" arrow (+) for yes to clear the menu and the
2. Remove cover (4) and four screws (2). "minus" arrow (-) (3) to cancel your selection and not
clear the Fault History.
3. Discharge the capacitors in the controller by con-
necting a load (such as a contactor coil or a horn) 10-2.4.Test the Fault Detection Circuitry
across the controller’s B+ and B- terminals.
1. Put the vehicle up on blocks to get the drive wheel
4. Remove any dirt or corrosion from the bus bar off the ground.
area. The controller should be wiped clean with a
2. Disconnect the battery and make sure the key-
moist rag. Allow it to dry before reconnecting the
switch is in the "OFF" position.
battery.
3. Using an inline fuse holder fitted with a 10 amp
5. Make sure the connections to the bus bars are
fuse and alligator clips, connect the controller's M
tight. Use two well insulated wrenches for this
and B- terminals.
task in order to avoid steering the bus bars.
4. Reconnect the battery and turn the key switch to
10-2.3.Diagnostic History the "ON" position. Release the brake and apply
The handheld programmer can be used to access the the throttle. The motor should not operate.
controller's diagnostic history file. When the program- 5. Leave the key switch on and remove the in-line
mer is connected to the unit, the error log file is auto- fuse wire. The vehicle status should continue to
matically uploaded into the handheld programmer. remain off.
To see the present status of the unit, use the Menu 6. Cycle the key switch off and on. Release the
Navigation Key (1, Figure 4-5) to select: brake and apply the throttle. The vehicle should
now operate normally.
Faults->System Faults.
To access this log, use the Menu Navigation Key to 10-2.5.Panel Removal.
select: 1. Turn off the key switch (9, Figure 12-8), discon-
Faults->Fault History nect switch (10) and disconnect the batteries.
The faults are shown as a code and descriptive text. If 2. Remove cover (4) and four screws (2).
there are multiple faults, you have to scroll through the 3. Tag and disconnect all electrical wires and cables
list using the Up and Down Buttons on the Menu Navi- which connect to the control panel (2, Figure 10-
gation Key 3).
The faults may be intermittent faults, faults caused by 4. Remove three screws and remove control panel
loose wires, or faults caused by operator errors. Faults (2).
such as HPD or over-temperature may be caused by
operator habits or by overloading. 10-2.6.Panel Disassembly.
After a problem has been diagnosed and corrected, Refer to Figure 10-3 for location and identity of the
clearing the diagnostic history file is recommended. major replacement components mounted on the panel
This allows the controller to accumulate a new file of and remove defective parts.
faults. By checking the new diagnostic history file at a
NOTE: The main contactor (6) and lift contactor (3)
later date, you can quickly determine whether the
used on this panel are not repairable and
problem has been completely fixed.
must be replaced if defective.
To clear the diagnostic history file, select:
10-4 901361
10-2.7.Panel Installation. 2. Remove cover (4) and four screws (2).
1. Install the control panel (2, Figure 10-3) and 3. Tag and disconnect all electrical connections from
secure with the three screws. horn (4, Figure 10-3).
2. Refer to Figure 10-3 and wiring schematic (Figure 4. Remove the screw, lock washer, washer, horn (4)
4-6) and connect all electrical wires and cables to and mounting spacer.
the control panel as noted during removal. 5. Check the capacitor for damage and replace as
3. Install cover (4, Figure 12-8) and four screws (2). necessary.
4. Reconnect the batteries and turn on the keyswitch 6. Install horn (4) with spacer, washer, lock washer,
(9) and switch (10). and screw.
7. Install cover (4, Figure 12-8) and four screws (2).
10-3.HORN REPLACEMENT
1. Turn off the key switch (9, Figure 12-8), discon- (9) and switch (10).
R6478
Figure 10-3 Electrical Panel
901361 10-5
10-4.PUMP MOTOR. 7. Loosen the mounting screw on each brush power
lead. Remove spring (15) from brush (16) and
The pump motor is replaceable but not repairable.
remove the brush.
Refer to paragraph 9-2.
8. Install new brush, reset brush spring and secure
10-5.DRIVE MOTOR. the electrical lead.
The drive motor exposed surfaces should be cleaned 9. Repeat Steps 7. and 8. for remaining brushes.
at least once a month to assure proper cooling of 10. Reinstall the shield (5) and two screws (4).
motor. Use an air hose to blow bust off of motor sur-
11. Reconnect the cables to the drive motor. Make
faces.
sure to match the cable label to the terminal.
10-5.1.Brush Inspection and Replacement CAUTION: Make sure that wires do not contact
The brushes can be inspected and replaced without sharp edges of any assembly. Vibration
removal of the motor. Proceed as follows: can cause the insulation to become
1. Turn off the key switch (9, Figure 12-8), discon- damaged leading to an electrical hazard.
nect switch (10) and disconnect the batteries. 12. Install cover (18, Figure 12-4) on transmission (8)
2. Remove four screws (2) and cover (4). and secure with four screws (19).
3. Remove four screws (5) and cover (6). 13. Reinstall cover (6, Figure 12-8) and four screws
4. Remove four screws (19, Figure 12-4) and cover (5).
(18) from transmission (8). 14. Reinstall cover (4) and four screws (2).
5. Tag the two outer cables connected to the drive 15. Reconnect the batteries and turn on the keyswitch
motor; then disconnect these two cables to pro- (9) and switch (10).
vide access. 16. Check for proper operation.
6. Remove two screws (4, Figure 10-4) and shield
(5).
R6464
Figure 10-4 Drive Motor
10-6 901361
10-5.2.Motor Removal 3. Position the new switch (5) on panel (2) and
secure with the two screws, washers, and mount-
ing plate.
6-1.
2. Note routing of cables to ensure proper installa- 4. Adjust the switch as described in paragraph 10-
tion. 6.2.
3. Tag the cables connected to the drive motor; then 10-6.2.Adjustment

disconnect these cables from the drive motor. 1. Raise the forks until switch (5) is aligned with the
4. Remove the four screws (20, Figure 12-4) and detent of mounting plate (7, Figure 12-8).
four washers (21) securing motor (15) to the
2. The detent should trigger the lift limit switch and
transmission.
stop the hydraulic pump and motor.
5. Remove motor (15) and O-ring (12). Discard the
3. If necessary, loosen screws (8) and adjust mount-
O-ring.
ing plate (7).
6. Remove nut (9), gear (11), and key (10) from the
4. Tighten screws (8) and recheck.
motor.
10-5.3.Motor Installation 10-7.DEADMAN SWITCH
1. Position key (10, Figure 12-4) and gear (11) on 10-7.1.Replacement

the shaft of motor (15) and secure with nut (9). 1. Disconnect wiring from the deadman switch (10,
2. Install drive motor with new O-ring (12) onto trans- Figure 12-5).
mission. Make sure to align gear (11) with the
2. Remove the two screws (11), washers, mounting
gear inside the transmission.
plate (12) and switch (10) from bracket (7).
3. Reinstall the four screws (20) and four washers
3. Position the new switch (7) on bracket (7) and
(21) to secure the motor to the transmission.
secure with the two screws (11), washers, and
4. Position cables as noted in removal and recon- mounting plate (12).
nect cables to the drive motor. Make sure to 4. Adjust the switch as described in paragraph 10-
match the cable label to the terminal. 7.2.
5. Reinstall the brake as described in paragraph
6-1. 10-7.2.Adjustment
1. Lower the control arm (7, Figure 12-1) until cam
10-6.LIFT LIMIT SWITCH (11) contracts the deadman switch (10, Figure 12-
5).
10-6.1.Replacement
2. The cam should trigger the deadman switch and a
1. Disconnect wiring from the lift limit switch (5, Fig- click should be heard.
ure 10-3).
3. If necessary, loosen screws (11) and adjust dead-
2. Remove the two screws, washers, mounting plate
man switch (10).
and switch (5) from panel (2).
4. Tighten screws (11) and recheck.
901361 10-7
NOTES
10-8 901361
SECTION 11
OPTIONAL EQUIPMENT
11-1.LOAD BACKREST. 11-2.CASTERS

A load backrest is available for addition to the lift truck Casters provide for additional stability. Installation of
to allow handling of high loads. Identification of the casters is shown in Figure 12-10 and repair parts
replacement parts, are shown in Figure 12-23. as shown in Figure 12-12.
901361 11-1
NOTES
11-2 901361
SECTION 12
ILLUSTRATED PARTS BREAKDOWN
Following is an illustrated parts breakdown of assemblies and parts associated with the PTE 45 Lift Truck.
901361 12-1
R6460
Figure 12-1 Steering Arm
12-2 901361
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — CONTROL HEAD (FIGURE 12-2) REF 11 902027 CAM 1
2 902062 HANDLE 1 12 902097 PIN 1
3 902139 SCREW 2 13 902082 NUT 1
4 902185 WASHER 2 14 902126 SCREW 1
5 902127 SCREW 1 15 902031 CHAIN 1
6 902407 PIN 1 16 902075 LINK-MASTER 1
7 902039 CONTROL ARM 1 17 902096 PIN 1
8 902154 SHEAVE 1 18 902160 SPRING 1
9 902149 SHAFT 1 19 902179 TUBE 1
10 902110 RING-SNAP 2
901361 12-3
R6461A
Figure 12-2 Control Head

— 902040 CONTROL HEAD 1 12 902164 . SPRING 6
1 902410 . EMERGENCY REVERSE 1 13 902137 . SCREW 6
SWITCH ASSY 14 902137 . SCREW 1
2 902047 . . EMERGENCY REVERSE 1 15 902412 . HORN SWITCH ASSY 1
BUTTON 16 902174 . . SWITCH 1
3 902174 . . SWITCH 1 17 902023 . . BUTTON-HORN 1
4 902163 . SPRING 4 18 902045 . COVER 1
5 902115 . RUBBER BUMPER 1 19 902413 . LOWER SWITCH ASSY 1
6 902173 . SWITCH BRACKET 1 20 902174 . . SWITCH 1
7 902137 . SCREW 2 21 902025 . . BUTTON-LOWER 1
8 902141 . SCREW 2 22 902170 . SUPPORT PLATE 1
9 902411 . LIFT SWITCH ASSY 1 23 902089 . NUT 1
10 902024 . . BUTTON-LIFT 1 24 — . CONTROL HEAD (FIGURE 12-3) REF
11 902174 . . SWITCH 1
12-4 901361
R6462
Figure 12-3 Control Head

— — CONTROL HEAD 1 11 902141 . SCREW 4
1 902104 . RACK 1 12 902059 . GEAR 1
2 902165 . SPRING 1 13 902079 . MOUNTING BRACKET 1
3 902166 . SPRING PIN 1 14 902102 . POTENTIOMETER 1
4 902028 . CAM 1 15 902172 . SWITCH BOX 1
5 902136 . SCREW 2 16 902056 . FLANGED BEARING 2
6 902175 . SWITCH 2 17 902029 . CAM SHAFT 1
7 902068 . ISOLATE BLOCK 1 18 902041 . CONTROL KNOB 2
8 902078 . MOUNTING BRACKET 1 19 902036 . CONNECTING WASHER 2
9 902183 . WASHER 4 20 902046 . COVER 2
10 902090 . NUT 2 21 902167 . SPRING PIN 2
901361 12-5
R6463

1 902061 GUARD 1 17 902053 DRUM-BRAKE 1
2 902080 NUT 1 18 902044 COVER 1
3 902181 WASHER 1 19 902132 SCREW 5
4 902004 BEARING 1 20 902131 SCREW 4
5 902005 BEARING 1 21 902182 WASHER 4
6 902144 SEAL 1 22 902013 BOLT 1
7 902109 BACKUP RING 1 23 902161 SPRING 1
8 — TRANSMISSION ASSY REF 24 902106 RETAINER 1
(FIGURE 12-5) 25 902074 LINK 1
9 902091 NUT 2 26 902194 YOKE ASSEMBLY 1
10 902069 KEY 2 27 902088 NUT 1
11 902058 GEAR 1 28 902111 ROD 1
12 902093 O-RING 1 29 902015 BRAKE ARM 1
13 902190 WHEEL ASSEMBLY 1 30 902010 BEARING 1
14 902084 NUT 1 31 902134 SCREW 1
15 — MOTOR ASSY (FIGURE 12-6) REF 32 902001 ANCHOR 1
16 — BRAKE ASSY (FIGURE 12-7) REF
12-6 901361
R6476A
Figure 12-5 Transmission Assembly

— 902177 TRANSMISSION ASSEMBLY 1 14 902435 . BEARING 2
1 902020 . BUMPER 1 15 — . FIXED SLEEVE 1
2 902114 . RUBBER BLOCK 1 16 — . CASE 1
3 902138 . SCREW 2 17 902436 . GEAR 1
4 902186 . WASHER 2 18 — . COVER 1
5 902099 . PLATE 1 19 — . SCREW 14
6 902116 . SCREW 4 20 — . BEARING 2
7 902014 . BRACKET 1 21 — . WASHER 1
8 902124 . SCREW 1 22 — . IDLER GEAR 1
9 902021 . BUSHING 2 23 — . PIN 2
10 — . SPRAY NOZZLE 2 24 — . SCREW 2
11 902434 . RING 1 25 902171 SWITCH 1
12 902432 . SEAL 1 26 — SCREW 2
13 902433 . O-RING 1 27 — MOUNTING PLATE 1
901361 12-7
R6464
Figure 12-6 Drive Motor

— 902077 DRIVE MOTOR 1 14 — . BEARING 2
1 — . SCREW 4 15 902169 . SPRING, BRUSH 4
2 — . LOCK WASHER 8 16 902018 . BRUSH 4
3 — . HEAD, COMMUTATOR END 1 17 902019 . BRUSH SOCKET 1
4 902141 . SCREW 2 18 — . WASHER 4
5 — . COVER 1 19 — . LOCK WASHER 4
6 — . NUT 4 20 — . SCREW 4
7 — . CLIP 4 21 — . STATOR 1
8 — . WASHER 2 22 — . ROTOR 1
9 — . WASHER 2 23 — . SNAP RING 1
10 — . WASHER 2 24 — . SEAL 1
11 — . WASHER 2 25 — . COVER 1
12 — . SCREW 2 26 — . SCREW 4
13 — . WAVE WASHER 1
12-8 901361
R6465
Figure 12-7 Brake Assembly

— 902016 BRAKE ASSEMBLY 1 4 902026 CAM 1
1 902162 SPRING 2 5 902100 PLATE 1
2 902155 SHOE 1 6 902071 LEVER 1
3 902133 SCREW 2 7 902033 CLIP 1
901361 12-9
R6474A
Figure 12-8 Compartment
12-10 901361
1 902050 DASH 1 7 902101 PLATE-MOUNTING 1
2 902143 SCREW 8 8 902123 SCREW 2
3 902156 SPACER 4 9 902070 KEY SWITCH 1
4 902048 COVER 1 — 902408 . KET SET A/R
5 902125 SCREW 4 10 902176 SWITCH-DISCONNECT 1
6 902178 TRANSMISSION COVER 1 11 902003 BATTERY INDICATOR 1
901361 12-11
R6485
Figure 12-9 Decals

1 056564 CAUTION DECAL 2 5 061334 NAMEPLATE 1
2 056617 FORWARD-REVERSE DECAL 1 6 066050 DRIVE SCREW 4
3 056499 NO RIDING DECAL 1 7 056632 BIG JOE DECAL 2
4 056613 OPER. INSTR. DECAL 1
12-12 901361
NOTES
901361 12-13
R6469
Figure 12-10 Frame
12-14 901361
1 902081 NUT 2 17 902112 PULL ROD 2
2 902032 WASHER 2 18 902130 SCREW 2
3 902135 SCREW 3 19 902150 SHAFT, PIVOT 2
4 — ELECTRIC PANEL 1 20 902118 SCREW 2
(FIGURE 12-17) 21 902152 SHAFT, PIVOT 2
5 — FRAME 1 22 902151 SHAFT, PIVOT 2
6 902012 BOLT 2 23 902072 LINK 4
7 902086 NUT 2 24 902117 SCREW 4
8 902087 NUT 2 25 902073 LINK 2
9 902192 WHEEL HOUSING, LH 1 26 902034 BEARING 4
10 902120 SCREW 2 27 — CARRIER FRAME 1
11 902147 SHAFT, PIVOT 2 28 902133 SCREW 2
12 — WHEEL ASSY, LOAD REF 29 — SKID BAR ASSEMBLY REF
(FIGURE 12-13) (STANDARD)
13 902193 WHEEL HOUSING, RH 1 (FIGURE 12-11)
14 902153 SHAFT, PIVOT 2 30 — CASTER ASSEMBLY REF
(OPTIONAL)
15 902119 SCREW 2
(FIGURE 12-12)
16 902011 BEARING 16
31 — SCREW 8
901361 12-15
R6531
Figure 12-11 Skid Bar Assembly (Standard)

— 902415 SKID BAR ASSEMBLY 2 3 902418 . WASHER 3
1 902416 . BRACKET 1 4 902419 . BOLT 2
2 902417 . WEAR BAR 2
12-16 901361
NOTES
901361 12-17
R6486
Figure 12-12 Caster Assembly (Optional)
12-18 901361
— 902409 CASTER ASSEMBLY 2 12 902113 . ROTARY SHAFT 1
2 902065 . HOUSING 1 13 902157 . SPACER 2
3 902098 . PIN-COTTER 1 14 902122 . SCREW 2
4 902083 . NUT 3 15 902009 . BEARING 1
5 902108 . RING 2 16 902022 . BUSHING 1
6 902006 . BEARING 2 17 902121 . SCREW 1
7 902146 . SEAL 2 18 902082 . NUT 1
8 902066 . HOUSING-WHEEL 1 19 902168 . SPRING SOCKET 1
9 902008 . BEARING 1 20 902159 . SPRING 1
10 902085 . NUT 1 21 902000 . ADJUSTING BOLT 1
11 902189 . WHEEL 1 22 902060 . GREASE FITTING 1
23 902414 . WASHER 6
901361 12-19
R6472
Figure 12-13 Load Wheel Assembly

— 902191 LOAD WHEEL ASSEMBLY 2 4 902148 . SHAFT 1
1 902145 . SEAL 2 5 902007 . BEARING 2
2 902107 . RING 2 6 902076 . LOAD WHEEL 1
3 902118 . SCREW 1
12-20 901361
R6532
Figure 12-14 Entry Rollers

— 902420 ENTRY ROLLER ASSEMBLY 2 4 902195 . BRACKET 1
1 902199 . WASHER 3 5 902198 . ROLLER 3
2 902197 . SCREW 2 6 — . COTTER PIN 3
3 902196 . SPACER 1 7 902200 . SHAFT 3
901361 12-21
R6534
Figure 12-15 Left Exit Rollers

— 902421 LEFT EXIT ROLLER ASSEMBY 1 4 902202 . ROLLER 3
1 902201 . BRACKET 1 5 902205 . SHOULDER BOLT 3
2 902203 . WASHER 2 6 902208 . SCREW 2
3 902204 . SCREW 2 7 902207 . SCREW 2
12-22 901361
R6533
Figure 12-16 Right Exit Rollers

— 902422 LEFT EXIT ROLLER ASSEMBY 2 4 902202 . ROLLER 3
1 902206 . BRACKET 1 5 902205 . SHOULDER BOLT 3
2 902203 . WASHER 2 6 902208 . SCREW 2
3 902204 . SCREW 2 7 902207 . SCREW 2
901361 12-23
R6478
Figure 12-17 Electrical Panel

1 902406 FUSE 1 6 902037 CONTACT, MAIN 1
2 — ELECTRICAL PANEL 1 7 902209 FUSE HOLDER 1
3 902038 CONTACT, LIFT 1 — 902210 FUSE, 10 AMP 1
4 902063 HORN 1 8 902042 CONTROLLER 1
— 902030 CAPACITOR 1 9 902562 BUS BAR 1
5 902171 SWITCH 1
12-24 901361
R6466
Figure 12-18 Hydraulic System

1 902049 CYLINDER, LIFT 1 4 902187 O-RING 1
2 902095 O-RING 1 8 902140 SCREW 4
3 902064 HOSE 1 9 — PUMP, MOTOR & RESERVOIR REF
ASSEMBLY (FIGURE 12-19)
901361 12-25
R6467
Figure 12-19 Pump, Motor & Reservoir Assembly
12-26 901361
— 902103 PUMP, MOTOR & RESERVOIR 1 7 902129 . SCREW 2
ASSEMBLY 8 902105 . RESERVOIR 1
1 902067 . HYDRAULIC PUMP MOTOR 1 9 902184 . WASHER 4
2 902035 . CONNECTING BEARING 1 10 902130 . SCREW 4
SLEEVE 11 902054 . ELBOW 1
3 902180 . VALVE ASSEMBLY 1 12 902017 . BREATHER 1
4 902094 . O-RING 1 15 902055 . ELECTROMAGNETIC COIL 1
5 902092 . PUMP 1 .
6 902128 . SCREW 2 .
901361 12-27
R6488
Figure 12-20 Battery Installation
12-28 901361
1 005401 CONNECTOR AND CABLE 1 5 077031 WASHER -FLAT, 1/4 4
ASSEMBLY 6 063477 SCREW-HX HD, 1/4-20 X 5/8 LG 4
2 077209 WASHER-LOCK, SPLIT, 1/4 6 7 — BATTERY AND CHARGER ASSY REF
3 063481 SCREW-HX HD, 1/4-20 X 1-1/5 LG 2 (FIGURE 12-21 OR
FIGURE 12-22)
4 402264 SPACER-CONNECTOR, BATT 1
901361 12-29
R6477
Figure 12-21 Battery and Charger Assy-Two 12V Batteries
12-30 901361
1 506565 BATTERY BOX WELDMENT 1 23 023011 WIRE-STRANDED, 10 AWG, A/R
BLACK
2 403688 SPACER - CONNECTOR 1
24 023036 WIRE-STRANDED, 10 AWG, A/R
3 068478 SCREW-SLRH, 1/4-20 X 1-1/4 LG 2
WHITE
4 077209 WASHER-LOCK, SPLIT, 1/4 2
25 005471 CONNECTOR-SPLICE, CRIMP, 10 5
5 059421 NUT-HEX, 1/4-20 2
AWG
6 071376 SCREW-PHTH, 10-32 X 1/2 LG 4
7 077207 WASHER-LOCK, SPLIT, #10 4 WHITE
8 059416 NUT-HEX, #10-32 2 27 023004 WIRE-STRANDED, 16 AWG, A/R
9 506122 CONNECTOR ASSY-CHARGER 1 GREEN
10 056680 DECAL-CHARGER 1 28 023018 WIRE-STRANDED, 16 AWG, A/R
11 077204 WASHER-LOCK, SPLIT, #6 2 BLACK
12 059412 NUT-HEX, #6-32 2 29 021262 TERMINAL-RING, 10 AWG 7
13 005454 CONNECTOR INLET- FLANGED, 1 30 003216 BATTERY-12 VOLT, GMF 2
AC-NON TWIST LOCK 31 021206 TERMINAL-RING, 1/4 DIA 1
13 005461 CONNECTOR INLET- FLANGED, 1 33 403605 SPACER-FOAM, BATTERY 2
AC, TWIST LOCK 34 077211 WASHER-LOCK, SPLIT, 3/8 2
14 506567-01 BATT CONNECTOR & CABLE 1 35 077210 WASHER-LOCK, SPLIT 5/16 2
ASSY
36 077030 WASHER-FLAT, #10 2
15 057511 GROMMET 1
— 004987 CHARGER KIT-24V, 25A 1
16 056113 TIE-HARNESS 5
37 904076 . TRANSFORMER 1
17 021718 TERMINAL-1/47 SPADE, 16 AWG 4
38 904075 . CIRCUIT BOARD ASSY 1
18 003403 CIRCUIT BREAKER 1
39 904074 . THERMISTOR 1
19 506568-01 BATTERY CABLE ASSY 1
40 055810 CORD-CHARGER-NON TWIST 1
20 404992 SPACER-BATTERY, 1/2 X 6 X 6 2 LOCK
21 055708 ADHESIVE-LIQUID NAILS A/R 41 23884 CORD-CHARGER-TWIST LOCK
22 023010 WIRE-STRANDED, 10 AWG, RED A/R
901361 12-31
R6489
Figure 12-22 Battery and Charger Assy-Four 6V Batteries
12-32 901361
1 506565 BATTERY BOX WELDMENT 1 22 023010 WIRE-STRANDED, 10 AWG, RED A/R
2 403688 SPACER - CONNECTOR 1 23 023011 WIRE-STRANDED, 10 AWG, A/R
BLACK
3 068478 SCREW-SLRH, 1/4-20 X 1-1/4 LG 2
4 077209 WASHER-LOCK, SPLIT, 1/4 6
WHITE
5 059421 NUT-HEX, 1/4-20 6
25 005471 CONNECTOR-SPLICE, CRIMP, 10 5
6 071376 SCREW-PHTH, 10-32 X 1/2 LG 2
AWG
7 077208 WASHER-LOCK, SPLIT, #10 2
8 059416 NUT-HEX, #10-32 2 WHITE
9 506122 CONNECTOR ASSY-CHARGER 1 27 023004 WIRE-STRANDED, 16 AWG, A/R
10 056680 DECAL-CHARGER 1 GREEN
11 077204 WASHER-LOCK, SPLIT, #6 2 28 023018 WIRE-STRANDED, 16 AWG, A/R
12 059412 NUT-HEX, #6-32 2 BLACK
13 005454 CONNECTOR INLET- FLANGED, 1 29 021262 TERMINAL-RING, 10 AWG 7
AC 30 003221 BATTERY-6 VOLT, GMF 4
14 506567-02 BATT CONNECTOR & CABLE 1 31 404306 RETAINER-BATTERY 1
ASSY 32 021206 TERMINAL-RING, 1/4 DIA 1
15 057511 GROMMET 1 33 075623-06 STUD-PRESS IN, 1/4-20 X 1.25 2
16 056113 TIE-HARNESS 5 — 004987 CHARGER KIT-24V, 25A 1
17 021718 TERMINAL-1/47 SPADE, 16 AWG 4 37 904076 . TRANSFORMER 1
18 003403 CIRCUIT BREAKER 1 38 904075 . CIRCUIT BOARD ASSY 1
19 504150-31 CABLE ASSY 1 39 904074 . THERMISTOR 1
20 504150-32 CABLE ASSY 1 40 055810 CORD-CHARGER 1
901361 12-33
R6475
Figure 12-23 Backrest
INDEX PART NO.

NO. NO. PART NAME REQD.
1 902002 BACKREST 1
2 902188 WASHER 4
3 902142 SCREW 4
12-34 901361
R6537
Figure 12-24 Wiring Components

1 902423 CABLE - CONTROLLER A2 TO 1 5 902427 CABLE - CONTROLLER A1 TO 1
DRIVE MOTOR A2 MAIN CONTACTOR
2 902424 CABLE - CONTROLLER A1 TO 1 6 902428 CABLE - LIFT CONTACTOR TO 1
DRIVE MOTOR A1 PUMP MOTOR B2
3 902425 HARNESS - BATTERY CONNEC- 1 7 902429 CABLE - PUMP MOTOR B- 1
TOR TO FUSE 8 902431 HARNESS - CONTROL HEAD TO 1
4 902426 HARNESS - BATTERY TO BAT- 1 ELECTRICAL PANEL
TERY CONNECTOR 9 — HARNESS - CONTROL HEAD 1
901361 12-35
NOTES
12-36 901361
Big Joe Manufacturing Company

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PTE 45 SERIES

Section Page Section Page

Section Page Section Page

Figure Page Figure Page

Table Page Table Page

1-2. GENERAL DESCRIPTION.

Figure 1-2. PTE 45 Lift Truck

2-1. GENERAL. • Do not overload truck. Check nameplate for load

ITEM PROCEDURE ITEM PROCEDURE

Truck No. Model No.

Check O.K. ( ) Need Maintenance

Figure 2-1 Sample of Operator Check List

Figure 2-4. Brake Actuation

2-5. DRIVING AND STOPPING PROCEDURES.

Figure 2-3. Pushbutton Switches 2-6. BELLY-BUTTON SWITCH.

2-9. LOADING AND UNLOADING.

3-1. GENERAL. Ultra-deep discharging of brand new batteries

NOTE: The battery charger includes an override

No. 2 Grease—Lithium base, general purpose.

No. 3 Hydraulic oil-Heavy duty with a viscosity of

No. 4 SAE 30 or 40 Engine lubricating oil

Figure 3-2 Lubrication Diagram

4-1. GENERAL With Braking: Trouble With Lifting Or Lowering, and

Table 4-1 Troubleshooting Chart

4-2. BATTERY CHARGER TROUBLESHOOTING 4-2.2. Thermistor

4-2.4. Power Transformer Testing

Figure 4-2. Battery Charger Wiring Diagram

Figure 4-3. Electrical Panel Parts

CAUTION: Put the vehicle up on blocks to get the

Turn the keyswitch off and make sure the

LED Code Explanation

3. Sequencing delay too short.

Figure 4-6 Wiring Diagram (Sheet 1)

Figure 4-6 Wiring Diagram (Sheet 1)

Figure 5-1. Control Head Switches

Figure 5-2. Control Head and Steering Arm

Figure 5-3 Drive Controls

6-1. BRAKES. 18. Install cover (4) and screws (2).

6-1.1. Adjustment. 6-1.2. Brake Shoe Replacement.

Figure 6-1 Drive Assembly

Figure 6-2 Brake Assembly

7-1. Drive Wheel. NOTE: Support the transmission assembly during

7-2. Transmission. 1. Raise forks.

Figure 7-1 Drive Assembly

Figure 7-2. Wheel Assembly

Figure 7-3 Entry Rollers

Figure 8-1 Frame

Figure 9-1 Hydraulic System

Figure 9-2 Hydraulic Power Unit

10-1.BATTERY AND CHARGER ASSEMBLY 10-1.4.Battery and Charger Assembly Installation

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

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

Figure 10-3 Electrical Panel

Figure 10-4 Drive Motor

3. Tag the cables connected to the drive motor; then 10-6.2.Adjustment

10-5.3.Motor Installation 10-7.DEADMAN SWITCH

1. Position key (10, Figure 12-4) and gear (11) on 10-7.1.Replacement

11-1.LOAD BACKREST. 11-2.CASTERS