Manual Price $35.

00

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

Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901354
REV. A 1104
 TABLE OF CONTENTS
Section Page
1 DESCRIPTION ............................................................1-1
1-1. INTRODUCTION. ............................................1-1
1-2. GENERAL DESCRIPTION...............................1-1
1-3. NAMEPLATE....................................................1-1
1-4. SAFETY FEATURES. ......................................1-2
1-5. OPTIONS. ........................................................1-2
2 OPERATION ...............................................................2-1
2-1. GENERAL. .......................................................2-1
2-2. OPERATING PRECAUTIONS. ........................2-1
2-3. GENERAL CONTROL OPERATION................2-1
2-4. DRIVING AND STOPPING PROCEDURES. ...2-1
2-5. BELLY-BUTTON SWITCH. ..............................2-3
2-6. STEERING ARM RETURN SPRING. ..............2-3
2-7. LIFT AND LOWER CONTROLS. .....................2-3
2-8. LOADING AND UNLOADING. .........................2-3
2-9. PARKING. ........................................................2-3
3 MAINTENANCE ..........................................................3-1
3-1. GENERAL. .......................................................3-1
3-2. OPERATOR DAILY CHECKS..........................3-1
3-3. MONTHLY AND QUARTERLY CHECKS. .......3-2
3-4. BATTERY CARE. .............................................3-2
3-4.1. GENERAL. .......................................................3-2
3-4.2. BATTERY REMOVAL. .....................................3-2
3-4.3. TESTING AND CHARGING BATTERY. ..........3-2
3-5. LUBRICATION. ................................................3-3
4 ADJUSTMENT AND REPAIR .....................................4-1
4-1. GENERAL. .......................................................4-1
4-2. PART NUMBER IDENTIFICATION..................4-1
4-3. STEERING ARM AND CONTROL HEAD. .......4-1
4-3.1. BELLY-BUTTON SWITCH ADJUSTMENT. .....4-1
4-3.2. POTENTIOMETER TESTING AND
ADJUSTMENT (TRANSISTOR UNITS
ONLY). .............................................................4-1
4-3.3. RESISTOR CONTROL HEAD SWITCH
REPLACEMENT...............................................4-2
4-3.4. TRANSISTOR CONTROL HEAD SWITCH
REPLACEMENT...............................................4-5
4-3.5. STEERING ARM. .............................................4-6
4-3.6. ELECTRICAL CONTROL CABLE
REPLACEMENT...............................................4-8
4-4. BRAKES. ........................................................ 4-10
4-4.1. ADJUSTMENT. .............................................. 4-10
4-4.2. REPLACEMENT OF BRAKE PADS............... 4-10
4-4.3. REPLACEMENT OF DEAD-MAN SWITCH. .. 4-12
4-5. TRANSMISSION, DRIVE MOTOR, DRIVE
WHEEL, AND PIVOT TUBE ASSEMBLY. ..... 4-12
4-5.1. TRANSMISSION AND PIVOT TUBE
ASSEMBLY REMOVAL.................................. 4-12
4-5.2. TRANSMISSION INITIAL DISASSEMBLY..... 4-12
4-5.3. DRIVE AXLE REMOVAL................................ 4-12
4-5.4. DRIVE MOTOR/BRAKE ASSEMBLY
REMOVAL. ..................................................... 4-13
4-5.5. DRIVE MOTOR SERVICING. ........................ 4-13
PTW1104
Section Page
4-6. BASE, FRAME, AND FORK SECTION. ........ 4-17
4-6.1. GENERAL...................................................... 4-17
4-6.2. LOAD WHEEL REPLACEMENT. .................. 4-17
4-6.3. FRAME ASSEMBLY: FORK SECTION
AND LIFT LINKAGE REPAIR AND
REPLACEMENT. ........................................... 4-18
4-7. ELECTRICAL................................................. 4-20
4-7.1. BATTERY REMOVAL AND REPLACEMENT 4-20
4-7.2. BATTERY CABLE ASSEMBLIES
REPLACEMENT. ........................................... 4-20
4-7.3. RESISTOR/CONTACTOR PANEL. ............... 4-20
4-7.4. TRANSISTOR/CONTACTOR PANEL -
TRANSISTOR TRUCKS. ............................... 4-23
4-7.5. HORN REPLACEMENT. ............................... 4-27
4-7.6. BATTERY CHARGER (Figure 4-24).............. 4-27
4-7.7. WIRE HARNESS TESTING. ......................... 4-27
4-7.8. WIRING. ........................................................ 4-27
4-8. HYDRAULICS................................................ 4-36
4-8.1. LINE AND FITTING REPLACEMENT. .......... 4-36
4-8.2. HYDRAULIC PUMP, MOTOR, AND
RESERVOIR ASSEMBLY. ............................ 4-38
4-8.3. LIFT CYLINDER REMOVAL.......................... 4-38
4-8.4. LIFT CYLINDER REPAIR. ............................. 4-39
4-8.5. HYDRAULIC PRESSURE ADJUSTMENT. ... 4-39
4-9. DECALS AND TRIM. ..................................... 4-39
4-9.1. PAINTING REQUIREMENTS. ....................... 4-39
4-9.2. DECALS AND PLATES. ................................ 4-39
5 OPTIONS.................................................................... 5-1
5-1. BATTERY DISCHARGE INDICATOR. ............ 5-1
5-1.1. BATTERY DISCHARGE INDICATOR
REPLACEMENT. ............................................. 5-1
5-2. HOURMETER.................................................. 5-1
5-2.1. HOURMETER REPLACEMENT...................... 5-1
5-3. KEYSWITCH. .................................................. 5-1
5-4. COLD CONDITIONING PACKAGE................. 5-1
5-5. LOAD BACKREST........................................... 5-2
5-6. CASTER .......................................................... 5-2
6 TROUBLESHOOTING................................................ 6-1
6-1. TROUBLESHOOTING CHART. ...................... 6-1
6-2. CONTACTOR AND SWITCH
TROUBLESHOOTING..................................... 6-3
6-2.1. CONTACTOR TESTING. ................................ 6-3
6-2.2. SWITCH TESTING. ......................................... 6-3
6-3. TRANSISTOR CONTROLLER
TROUBLESHOOTING..................................... 6-6
6-3.1. CIRCUIT OPERATION. ................................... 6-6
6-3.2. GENERAL CHECKOUT (SERIAL NUMBER
373234 TO 376836)......................................... 6-9
6-3.3. TROUBLESHOOTING (PRIOR TO SERIAL
NUMBER 373234). ........................................ 6-10
6-3.4. DIAGNOSTICS AND TROUBLESHOOTING
(SERIAL NUMBER 373234 TO 376836). ...... 6-13
i
 TABLE OF CONTENTS (Cont)

Section Page Section Page

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

LIST OF ILLUSTRATIONS

Figure Page Figure Page

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

ii PTW1104
 LIST OF ILLUSTRATIONS (Cont)

Figure Page Figure Page

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

LIST OF TABLES

Table Page Table Page

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

PTW1104 iii
 NOTES

iv PTW1104
 SECTION 1
DESCRIPTION

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

R5140

Figure 1-1. PTW-40 Lift Truck

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

1-2 PTW1104
 SECTION 2
OPERATION
2-1. GENERAL.
This section gives detailed instructions for the PTW 40
lift truck. Information is applicable to resistor and tran-
sistor trucks, in 24 volt configurations. The instructions
are divided into the various phases of operations, such
as operating lift, driving, and stopping. Routine pre-
cautions are included for safe operation.
2-2. OPERATING PRECAUTIONS.
WARNING: Improper operation of the lift truck may
result in operator injury, or load and/or lift
truck damage. Observe the following
precautions when operating the PTW lift
truck.
1. Do not operate this truck unless you have been
trained and authorized to do so and have read all
warnings and instructions in this manual and on
the truck.
2. Do not operate this truck until you have checked
its condition. Give special attention to Tires, Horn,
Battery, Controller, Lift System, Brakes, Steering
Mechanism, Guards and Safety Devices.
3. Operate truck only from designated operation
position. Wear foot protection. Do not carry pas-
sengers.
4. Observe applicable traffic regulations. Yield right
of way to pedestrians. Slow down and sound horn
at cross aisles and wherever vision is obstructed.
5. 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.
6. Always look in direction of travel. Keep a clear
view, and when load interferes with visibility, travel
with load or lifting mechanism trailing.
7. Use special care when operating on ramps-travel
slowly, and do not angle or turn. Travel with lifting
mechanism or load downhill.
8. Do not overload truck. Check capacity plate for
load weight and load center information.
9. Before lifting, be sure load is centered, forks are
completely under load, and load is as far back as
possible against load backrest.
PTW1104
10. Do not handle loads which are higher than the
load backrest unless load is secured so that no
part of it could fall backward.
11. When leaving truck, neutralize travel control. Fully
lower lifting mechanism and set brake. When
leaving truck unattended, disconnect battery.
2-3. GENERAL CONTROL OPERATION.
The speed control (See Figure 2-1) located on each
side of the control head provides fingertip control for
driving the truck. As the lower portion of the speed
control is pressed, it closes contacts for first speed in
the forward direction. Pressing the speed control far-
ther closes a contact for second speed and farther,
third speed. The upper portion of the speed control
governs the reverse speeds in the same manner.
Pushbutton switches, located behind the belly button
switch guard, activate the lift-lower controls and the
horn.
Lowering the steering arm to the horizontal or raising
to the vertical applies the brake. (See Figure 2-2) All
traction control power is shut off when the brake is
engaged. When the steering arm is in the upright posi-
tion, the brake acts as a parking brake. Deadman
braking occurs when the handle is released and spring
action raises it to the upright position.
2-4. DRIVING AND STOPPING PROCEDURES.
1. Grasp the grips of the steering arm so that the
speed control can be comfortably operated by
either thumb. If equipped, turn on the key switch.
2. Lower the steering arm to a comfortable position
above horizontal to disengage the brake and to
energize the electrical circuits.
3. To move forward (with load trailing), slowly press
the lower portion of the speed control. Press the
forward speed control farther to increase speed.
Third speed may be cut out by use of the high
speed cut out switch (optional on transistor lift
trucks).
4. To stop, release the speed control and lower the
steering arm to the horizontal position. In this
position, the brake pads apply pressure to the
brake disc. Lowering the steering arm farther,
increases the braking force. The brake may also
be applied by raising the steering arm to the
upright position.
2-1
 R5095

Figure 2-1. Steering Arm Controls

R3629

Figure 2-2. Brake

2-2 PTW1104
NOTE: Procedures for movement in reverse are the
same as in the forward direction.
5. To travel in reverse, lower steering arm to a com-
fortable position above horizontal and slowly
press upper portion of speed control.
2-5. BELLY-BUTTON SWITCH. (Figure 2-1)
The belly-button switch minimizes the possibility of the
driver being pinned by the steering arm while driving
the lift truck in slow speed, forward. If the guard
presses against the operator while the lift truck is
being driven in forward, the guard actuates a switch
which changes the direction of the lift truck to reverse
direction in low speed.
2-6. STEERING ARM RETURN SPRING.
The steering arm return spring automatically raises
the steering arm to the upright position when the
steering arm is released. If the steering arm snaps up
abruptly, or does not return fully, the steering arm
return spring requires adjustment. Return truck to
maintenance for adjustment.
2-7. LIFT AND LOWER CONTROLS.
Lift/Lower Control buttons are located on the steering
control head, behind the belly button switch guard.
(Figure 2-1)
PTW1104
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.
2-8. LOADING AND UNLOADING.
1. Move truck to location where load is to be picked
up.
2. Move truck into position so forks are within pallet
or skid, and the load is centered over the forks
and as far back as possible.
3. Raise forks to lift load.
4. Drive to area where load is to be placed.
5. Move truck to align load with its new position.
6. Lower the load until it rests squarely in place and
the forks are free.
7. Slowly move the truck straight backward, using
the FORWARD speed control, to remove forks
from pallet.
2-9. PARKING.
When finished with moving loads, drive truck to its
maintenance or storage area. If equipped, turn off the
key switch. Disconnect batteries from TO DRIVE
receptacle and connect to the TO CHARGE recepta-
cle. Charge batteries as necessary. Refer to battery
care instructions, paragraph 3-4.
2-3
 NOTES

2-4 PTW1104
 SECTION 3
MAINTENANCE

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

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

Table 3-1. Daily Checks

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

PTW1104 3-1
 Table 3-2. Monthly and Quarterly Inspection and Service Chart
INTERVAL INSPECTION OR SERVICE
Monthly Clean drive motor and check condition of commutator, brushes and springs
(Paragraph 4-5).
Monthly Clean pump motor and check condition of commutator, brushes and springs
(Paragraph 4-8).
Monthly Check mechanical brake linkage for proper operation.
Monthly Check load wheels for wear. A poly load wheel must be replaced if worn to within 1/16 inch
of hub. Check for separation from hub.
Monthly Check drive wheel for wear. A poly load wheel must be replaced if worn to within 1/16 inch
of hub. Check for separation from hub.
Monthly Inspect wiring for loose connections and damaged insulation.
Monthly Inspect contactor tips for excessive pitting and wear.
Monthly Check deadman brake switch for proper operation.
Quarterly Check lift cylinders for leakage.
Quarterly Check for excessive jerking of steering arm when stopping or starting.
Quarterly Check brake pads for wear. Both brake pads must be replaced when pad material of either
one is worn to rivet head surface.

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

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

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

4. After charging, check water level in each cell

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

PTW1104 3-3
 Table 3-4. Lubrication Chart

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

Interval Index No. Application (Table 3-4)
160 Hours 1 Channel Brush No. 2 Accessed through battery compartment.
Brush generous amount of lubricant in
middle of channel. If rollers squeak, lower
forks slightly and apply grease directly to
rollers; operate forks up and down a few
times to coat forks up and down a few
times to coat lift carriage channels.
Semi- 2 Steering Arm Can No. 4 1 or 2 drops each time serviced.
Annually Elbow
Annually 3 Transmission Can No. 1 Fill to plug level.
Housing
Semi- 4 Hydraulic Can No. 3 Lower carriage, fill to 1 inch below elbow
Annually Reservoir tap in reservoir.
40 Hours 5 Lift Linkage Sleeve Can No. 4 1 or 2 drops each time serviced. (20 bush-
Bushings ings)
Semi- 6 Pivot Tube Can No. 4 1 or 2 drops each time serviced.
Annually Bushings

R5141

Figure 3-1. Lubrication Diagram

3-4 PTW1104
 SECTION 4
ADJUSTMENT AND REPAIR
4-1. GENERAL.
This section contains information and procedures for
maintenance of the PTW lift trucks. Maintenance
includes adjustment, and repair.
This section contains illustrations identifying mainte-
nance parts. The callouts on each illustration corre-
spond to the reference index numbers in the
applicable text.
Parts listings are provided in SECTION 7 of this man-
ual. The part list provides the Big Joe Manufacturing
Company part number, the part description, and the
quantity of the part required in the assembly.
When identifying each part to be ordered, visually
compare the part in the illustration with the actual part
needed. To assure proper identification of each part
being ordered, include your truck model number, your
truck serial number (see nameplate), the part number
description, and quantity of the part(s) needed. If the
nameplate becomes lost or illegible, refer to Figure 1-1
for other serial number locations.
4-2. PART NUMBER IDENTIFICATION.
To determine the part number of a replacement part,
identify the assembly in which the part is used and
locate the illustration (in SECTION 7) of the applicable
assembly. Find the index number for the part on the
illustration and refer to that index number in the parts
list. If the part number is NP, order the next higher
assembly. If the part number is VAR, order by part
name with truck model number and serial number.
If the part is listed with more than one part number,
select the proper part number by comparing the
description in the parts list with the specifications of
your truck. Refer to the nameplate to determine appli-
cation to your truck.
4-3. STEERING ARM AND CONTROL HEAD.
4-3.1. Belly-Button Switch Adjustment.
If the actuator gap of the belly-button switch needs
adjustment, proceed as follows (Figure 4-1):
1. Disconnect the battery.
2. Drive out the roll pins that secure the belly-button
casting (Figure 4-1). Drive from the left to the
right.
PTW1104
NOTE: While removing the belly-button casting, the
two return springs will drop free. Catch the
springs while pulling the casting away to pre-
vent their loss. Resistor lift trucks have one
belly-button switch, transistor trucks have a
stack of three.
3. Bend actuator levers of belly-button switch(es) to
adjust gap between rollers and belly-button cast-
ing as required (See Figure 4-1).
CAUTION: If too small a gap exists between belly-
button switch actuator rollers and the
belly-button casting, the belly-button
switch(es) may be actuated constantly.
4. Reinstall belly-button casting, making certain all
parts are back in place.
5. Check operation of the belly-button safety
switch(es) by pressing the belly-button casting
while listening for the "click" that indicates that the
switch(es) have actuated.
NOTE: The click should be heard when the belly-but-
ton casting has moved about 50 percent of its
normal travel distance. If the click is heard at
the beginning of travel, the switch(es) may
actuate at inappropriate times. If the click is
heard near the end of travel, they could be
unreliable and may not switch in some
instances.
6. Repeat steps 2. through 5. until pressing the
belly-button casting actuates the switch(es) prop-
erly.
7. Reconnect the battery.
WARNING: Testing of belly-button safety switch(es)
in operation should be limited to areas
clear of obstacles against which an oper-
ator could be pinned. Use low speed in
forward.
4-3.2. Potentiometer Testing and Adjustment
(Transistor Units Only).
1. Disconnect the battery
2. Remove screws (20 and 64, Figure 4-3) and
access covers (40 and 66).
4-1
 R5097
Figure 4-1. Belly-Button Switch and Potentiometer Adjustment
3. Check gap between rollers on directional switches
(7) and surface of cam (46). If required, adjust
position of bracket (50) to obtain a 0.03 - 0.06 inch
clearance.
4. Disconnect the pin and receptacle housings
located at contactor panel, connecting the control
cable (3, Figure 4-19) and wire harness (39, Fig-
ure 4-20, 21, Figure 4-21 or 12, Figure 4-22). Set
an ohmmeter to the RX1K (1000) scale and con-
nect across pin contacts of wires 4 and 11 at the
control cable (3, Figure 4-19) pin housing.
5. Slowly press the control lever (52, Figure 4-3) in
the forward direction until a click indicating for-
ward switch closure is heard. Ohmmeter should
indicate 4550 ± 250 OHMS.
6. If incorrect reading is obtained, use access hole,
in side of control head (Figure 4-1) to gain access
to the potentiometer, (3, Figure 4-3). Insert a
screwdriver blade into the slot on the back side of
the potentiometer (Figure 4-1) and turn slightly.
Vary the amount and direction of screwdriver rota-
tion until the specified value is achieved.
7. Repeat step 5 while pressing control lever in
reverse direction. Meter readings should be the
same as for the forward direction (± 200 OHMS).
If meter readings are not the same, adjust position
of bracket (44, Figure 4-3) as necessary to obtain
the same values. Adjust the potentiometer again if
necessary.
4-2
8. Rotate cam (46) in both forward and reverse
directions, until it stops. Verify that bypass switch
(7) closes in each direction, just prior to the stop.
9. Reassemble the control head.
4-3.3. Resistor Control Head Switch Replacement.
1. Disconnect the battery.
NOTE: Access to belly-button switch (3, Figure 4-2)
is provided by removal of safety cover (42);
access to other switches is provided by
removal of top cover (54), bottom cover (30),
and switch plate (55).
2. Refer to paragraph 4-3.1. if necessary to gain
access to a defective belly-button switch.
NOTE: Switch operation may be checked with a con-
tinuity light containing a battery, or with an
ohmmeter.
3. Replace a defective belly-button switch (3) as fol-
lows:
a. Remove locknuts (7) and screws (19) to
release belly-button switch (3) and insulator
(2).
b. Tag and disconnect electrical wires from
belly-button switch (3).
c. Connect electrical wires to new belly-button
switch (3), as noted during removal.
PTW1104
 R5098

Figure 4-2. Control Head Assembly - Resistor

PTW1104 4-3
 R5099

Figure 4-3. Control Head Assembly - Transistor

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

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

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

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

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

4-6 PTW1104
 b. Remove control head (Paragraph 4-3.4.,
above).
CAUTION: The steering arm (17) has a tendency to
fall downward when the tension on the
CAUTION:
return spring (10) is released.
c. Hold steering arm (17) and make sure the
arm cannot fall.
d. With a piece of chalk or crayon, draw a
straight line from center of spring tube (11,
Figure 4-4) outward onto pivot cap (4, Figure
4-9), marking radial position of tube to facili-
tate re-installation.
e. Insert a 5/16-inch Allen wrench through hole
in bottom of steering arm (17, Figure 4-4).
R5100
Figure 4-4. Steering Arm
PTW1104
Loosen and remove screw (15) and spacer
(14).
f. Disconnect brake rod (19) from clamp (8).
Unless properly supported, steering arm
(17) will drop out of pivot cap (4, Figure
4-9) when spring tube (11, Figure 4-4) is
removed.
g. Put a block under steering arm (17) at pivot
cap (4, Figure 4-9).
h. With a pair of vise-grip pliers, grip the flat sur-
faces of spring tube (11, Figure 4-4) and
slowly pull it free from the steering arm (17),
pivot cap (4, Figure 4-9) and tube clamp (8,
Figure 4-4).
4-7
NOTE: The flat surfaces are on the protruding end of
the spring tube (11), where the pins (12 and
13) are installed. Steering arm return spring
(10) will remain inside the spring tube (11).
i. Remove steering arm return spring (10) from
spring tube (11). If spring is severely jammed
and will not come loose, use punch and drive
the 1/4-inch diameter roll pin (13) into the
tube. Save pin for re-use. Remove the spring.
Tap roll pin back into place.
j. Lubricate the ends and the outer surface of
the new steering arm return spring (10) with
a lithium base general purpose grease.
k. Insert spring (10) into spring tube (11) and
press in, making sure that one spring loop
eye fits over the 3/8-inch pin (12) at the
closed end of the spring tube.
l. Slide spring tube (11) into pivot cap (4, Fig-
ure 4-9) and steering arm (17, Figure 4-4)
through tube clamp (8) and through loop of
electrical cable. Slowly rotate spring tube a
few degrees each way until the steering arm
return spring (10) snaps into place over
spring pin (5). Refer to Figure 4-5 for internal
view of steering arm with return spring
installed.
m. Connect brake rod (19, Figure 4-4) to clamp
(8), securing with new cotter pin (7). Install
spacer (14) and screw (15), but do not
tighten. Align radial position of spring tube
(11) in accordance with line drawn in step e.
Tighten screw (15).
n. Remove block from under steering arm.
o. Install control head.
p. Refer to paragraph 4-3.5., step 1, above, and,
if necessary, adjust the tension on steering
arm return spring.
q. Reconnect battery.
4-3.6. Electrical Control Cable Replacement.
1. Disconnect battery.
2. Remove 4 screws (11, Figure 4-5) that fasten con-
trol head assembly to steering arm.
3. Disconnect the exposed connector (5).
4. Remove cable clamps (1 and 2) and loosen loop
of cable that is around the spring tube assembly
(3).
5. Remove pivot cap (10).
4-8
6. Cut off connector (5) from end of cable.
7. Pull loose end of cable up, and let it extend
through top of pivot tube (12).
8. Remove screws (3, Figure 4-13), nuts (10), lock-
washers (4), flat washers (9), and motor compart-
ment (service) cover (1).
9. Disconnect connector (7, Figure 4-5).
10. Refer to Figure 4-17 for resistor trucks, or Figure
4-19 for transistor trucks. Remove wire tires and
clamps (5), as required to free control cable (3).
Note routing of cable, and position of wire ties and
cable clamps, to ensure proper installation.
11. Using a suitable pin removal tool, tag and remove
dead-man switch cable leads from pin locations
13 and 14 in connector (7, Figure 4-5).
12. Using a suitable pin removal tool, remove wires
from pin locations 1 through 12 in connector (7)
on the new replacement control cable.
13. Tape the cut end of the old cable to the wires just
removed from connector (7) on the new cable.
14. Grease the new cable with a lithium base grease
or silicone spray.
15. Draw new cable into pivot tube (12) by pulling old
cable out through opening in transmission hous-
ing.
16. Secure connector (5) end of new cable, to prevent
it from falling in pivot tube (12).
17. Remove old cable from new cable and wipe off
excess grease.
18. Insert wires 1 through 12 into pin locations 1
through 12, respectively, in connector (7).
19. Insert dead-man switch cable leads into pin loca-
tions 13 and 14 in connector (7), as noted during
removal.
20. Route new control cable, as noted during
removal.
21. Group all cables coming from drive motor, dead-
man switch and control cable, and clamp as
shown on Figure 4-17 or Figure 4-19.
22. Secure cables to transmission housing and power
section frame with clamps (5) and associated
hardware. Use wire ties to bundle cables and
wires as noted during removal.
23. Connect connector (7, Figure 4-5).
24. Using a suitable pin removal tool, remove wires
from pin locations 1 through 12 in connector (5).
Tape the wire ends together.
PTW1104
25. Pull the connectorless end of cable (4) over pin
(14) and under spring tube assembly (3).
26. Eliminate excess cable slack in pivot tube (12);
then secure cable with cable clamp (1).
27. Loop cable around spring tube assembly as illus-
trated (Figure 4-5) and push connector end of
cable into steering arm.
CAUTION: Improper cable loop adjustment will
damage cable. If too tight, cable will tear
when steering arm is in up position. If too
loose, cable will buckle or be pinched
when steering arm is in down position.
28. Pull the cable until it is wrapped firmly around the
spring tube assembly (3). Slack off approximately
1/2 inch and secure the cable in this position with
cable clamp (2).
R5101
Figure 4-5. Electrical Control Cable Replacement
PTW1104
29. Work steering arm up and down a few times to
assure that the electrical control cable is not bind-
ing.
30. Pivot transmission through entire turning range,
observing that all electrical cables and wire leads
will flex properly and not become caught or
pinched at any time.
31. Reinstall wires 1 through 12 into pin locations 1
through 12, respectively in connector (5).
32. Reinstall the control head assembly, engaging
connector (5) to end of speed control harness (3,
Figure 4-17 or Figure 4-19) and secure with
screws (7, Figure 4-5).
33. Install pivot cap (10).
34. Install motor compartment (service) cover (1, Fig-
ure 4-13) and secure with flat washers (9), lock-
washers (4), nuts (11), and screws (3).
35. Connect the battery.
4-9
4-4. BRAKES.

4-4.1. Adjustment.
Adjust the brake if it does not engage when the steer-
ing arm is raised to within 15 degrees from its park
position or lowered to within 15 degrees from its lowest
position (Figure 2-2). Proceed as follows:
1. Disconnect battery.
2. Jack up the truck so the drive wheel is off the
ground; then securely block the truck to prevent
slipping.
3. Remove screws (3, Figure 4-13), nuts (10), lock-
washers (4), flat washers (9), and motor compart-
ment (service) cover (1). R5142

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

6. Remove the cotter pin (1, Figure 4-6), then slide f. Install service cover (1, Figure 4-13), flat
the rod (2) into the brake lever (3) far enough to washers (9), lockwashers (4), nuts (10), and
pull the link pin (4) out of the lever (5). screws (3).
7. Turn the link pin (4) to make the adjustment. g. Connect battery connector.
8. Slide the link pin (4) back into the lever (5), but do 4-4.2. Replacement of Brake Pads.
not insert the cotter pin (1) at this time.
1. Disconnect the battery.
9. Turn the drive wheel by hand to check brake
adjustment. If there is noticeable drag, go to step 2. Block the wheels to prevent the truck from rolling.
12. If there is no drag, go to step 10.
10. Disconnect the link pin (4).
11. Repeat steps 7 through 9 until adjustment is cor-
rect providing noticeable drag.
12. Install the cotter pin (1).
13. Secure the steering arm in drive position and spin
the drive wheel to make sure there is no drag. If
there is any drag, carefully readjust only enough
to eliminate drag in the drive position.
14. Adjust dead-man switch (1, Figure 4-7) as follows:
a. Allow steering arm (17, Figure 4-4) to return
to the upright position.
b. Check that brake lever (15, Figure 4-8) has R5143

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

4-10 PTW1104
 R5144

Figure 4-8. Brake and Linkage

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

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

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

4-5.1. Transmission and Pivot Tube Assembly

Removal.

4-12 PTW1104
 3. Make sure the four cables to the drive motor are
properly labeled A1, A2, F1, and F2; then discon-
nect the cables from the drive motor.
4. Remove the four bolts (2, Figure 4-10) and lock
washers (3) that hold motor mounting plate (4).
5. Tap motor mounting plate loose and remove
mounting plate with brake assembly bearings,
bearing housing, seal, washer, and gear as a sin-
gle piece.
6. If further disassembly is required remove pin (18)
from gear (17) and proceed with disassembly.

NOTE: During reassembly be sure all parts are prop-

erly sequenced on armature shaft and that
dowel pins in motor mounting plate are
aligned with corresponding holes in transmis-
sion housing.

4-5.5. Drive Motor Servicing.

R5310
Figure 4-9. Pivot Cap and Tube Installation
4-5.4. Drive Motor/Brake Assembly Removal.
1. Perform the initial disassembly, steps 1 through 8.
2. Remove the cotter pin that fastens the brake rod
to the brake caliper lever.
The drive motor exposed surfaces should be cleaned
at least once a month to assure proper cooling of
motor. Use an air hose to blow bust off of motor sur-
faces. If the truck does not run and the drive motor is
at fault, inspect brushes (4, Figure 4-11 or 6, Figure 4-
12) and commutator (on armature). Replace brushes if
they are worn. Clean commutator of rough spots with
fine sand paper and remove accumulations of loose
particles.
If the motor is to be disassembled, remove it from the
transmission as follows:
1. Disconnect the battery.
2. Make sure the four cables to the drive motor are
properly labeled A1, A2, F1, and F2; then discon-
nect the cables from the drive motor.
3. Remove the four screws holding the motor mount-
ing plate to the transmission.
NOTE: The motor mounting plate is positioned by
dowel pins and must be tapped loose when
removing the plate from the transmission.
4. Tap the motor mounting plate loose and remove
the mounting plate with motor, brake caliper,
brake disc and gear attached to armature shaft.
NOTE: Testing information available in Big Joe Motor
Maintenance Manual.
5. When reinstalling motor on transmission, be sure
dowel pins are properly positioned so that arma-
ture will line up with bushing in transmission; then
tap motor mounting plate in place and fasten with
four screws.

PTW1104 4-13
 R5311

Figure 4-10. Transmission Assembly

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

R5312

Figure 4-11. Drive Motor Assembly

USED ON TRUCKS
SERIAL NUMBERS
371794 TO 376836

R6109

Figure 4-12. Drive Motor Assembly

PTW1104 4-15
 R5313

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

4-16 PTW1104
4-6. BASE, FRAME, AND FORK SECTION.
4-6.1. General.
The base and frame section of the truck includes the
information plates, decals, fork section, and load
wheels.
Removal and replacement of covers is straight-forward
and does not require detailed information, See Figure
4-13. Make certain that all decals remain on the truck
and are legible. If decals are damaged or missing they
must be replaced, See Figure 1-1.
4-6.2. Load Wheel Replacement.
1. Raise the forks.
2. Block the drive wheel to prevent the truck from
rolling.
3. Jack the forks up high enough to lift the load
wheels off the floor and block securely under the
tips of the forks.
4. Drive the pin (5, Figure 4-14) from the shaft (11),
and pull the shaft out of the wheel housing (9),
R5314
Figure 4-14. Fork Section Assembly
PTW1104
freeing the load wheel (6). Be careful not to lose
the spacers (8).
NOTE: If load wheels are worn appreciably, it is rec-
ommended that both front wheels be
replaced to assure equal load distribution on
the wheels.
5. Check bearings (7) for damage; rotate by hand,
checking for smooth, non-binding rotation.
6. If either bearing (7) or the load wheel (6) is dam-
aged, the entire load wheel assembly must be
replaced.
7. Install the load wheels as follows. One load wheel
is installed in each wheel housing (9).
a. Start the shaft (11) into the wheel housing
(9).
b. While sliding the shaft (11) completely into
the wheel housing (9), install one spacer (8),
the load wheel (6) and another spacer (8), in
that order, onto the shaft (11).
c. Secure the shaft (11) by installing the pin (5).
4-17
8. Remove blocking and lower forks to the ground.
4-6.3. Frame Assembly: Fork Section and Lift
Linkage Repair and Replacement.
1. Lift Linkage repair and replacement:
a. Lift complete truck to height sufficient to per-
mit access to lift linkage under forks. Provide
blocking under power section frame and at
tips of forks.
b. Drive pin (23, Figure 4-14) from shaft (28)
and pivot (24). Support the pivot (24) and
linkage. Remove shaft (28) and washers
(13). Remove springs (21) and lower the
pivot (24) and linkage toward the floor.
c. Drive pin (3) from shaft (4) in fork. Support
the wheel housing assembly and linkage.
Remove shaft (4) and washers (13). Remove
wheel housing assembly and assembled link-
age from the fork section (1).
d. Drive pin (5) from shaft (12) and wheel hous-
ing (9). remove shaft (12) and washers (12),
separating wheel housing (9) from rod (14).
e. If necessary for repair or replacement of
wheel housing (9) remove load wheels (Para-
graph 4-6.2.).
f. Drive pin (23) from shaft (22) and pivot (24).
Remove shaft (22) and washers (13), sepa-
rating pivot from rod (16).
g. Drive pin (23) from shaft (22) and pivot (24).
Remove shaft (22), washers (13) and roller
assembly (26) from pivot (24).
NOTE: Do not separate adjustable pull rods (14 and
16), and turnbuckle (20) unless necessary for
rod replacement.
h. If wheel housing (9), rod (14 or 16), or roller
(26) must be replaced with a new part, omit
step i, below, for that component.
i. Inspect sleeve bushings (10, 15, 17 and 27)
for excessive wear or other damage. Sleeve
bushings must be replaced if wall thickness
of bushing is less than 1/16 inch. Press in
new bushings so they are flush with outside
edges within 0.02 inch. After installation,
ream, if required, to bring bushing ID to 0.622
+0.002/-0.000 inches.
j. Position roller assembly (26) with washers
(13), as necessary, in pivot (24). Install shaft
4-18
(22) through pivot, washers and roller assem-
bly, securing with pin (23).
k. If adjustable pull rods (14 and 16) were sepa-
rated, assembly as follows:
(1) Install nut (18) and lockwasher (19) fully
onto front pull rod (14).
(2) Thread turnbuckle (20) approximately
1-3/4" onto rod (14).
(3) Thread rear pull rod (16) approximately
1-3/4" into turnbuckle (20).
l. Position rod (16) with washers (13), as
required, in pivot (24). Ensure that the spring
bracket on rod raps around the underside of
rod, and install shaft (22). Secure shaft with
pin (23).
m. Position rod (14) with washers (13), as
required, in wheel housing (9). Install shaft
(12) through wheel housing, washers and
front rod end, securing with pin (5).
n. Position wheel housing (9) and washers (13)
as needed in fork section. Install shaft (4) and
secure shaft with pin (3).
o. Position pivot (24) to align pivot bore with
bore in rear of fork and add washers (13) as
needed. Install shaft (28) and secure with pin
(23). Attach springs (21) to each side of rod
(16) and underside of fork.
p. Adjust the pull rods as follows:
(1) Clamp the wheel housing (9) in place as
shown in Figure 4-15.
(2) Measure the 18.38" dimension as shown
in Figure 4-15. If measurement is within
tolerance, pull rod does not need adjust-
ment.
(3) If adjustment is required, loosen the jam
nut and adjust the turnbuckle as required
to provide the 18.38" dimension.
(4) Lock adjustment by tightening the jam
nut.
(5) Remove the clamp.
(6) Adjust other pull rod in same manner.
q. If removed, install load wheels (Paragraph
4-6.2. above).
r. Repeat steps b thru q, to repair/replace lift
linkage of other fork.
PTW1104
 R5333
Figure 4-15. Pull Rod Adjustment Details
2. Fork Section and Power Section Frame Separa-
tion:
a. Support entire truck on blocking, providing
separate blocks so that the fork section can
be fully supported when power section is
removed.
b. Disconnect battery.
c. Remove batteries (Paragraph 4-7.).
d. Remove cover (1, Figure 4-13).
e. Ensure that hydraulic pressure has been
relieved from the lift circuit. Disconnect
hydraulic line from fitting at cylinder and
remove the fitting.
WARNING: Power section is heavy. Use care while
securing and lifting in order to prevent
injury.
f. With suitable hoist, carefully lower the power
section (11, Figure 4-13) slightly, so cylinder
rod end will clear socket in fork section. With
access through battery compartment of
power section, raise or lower power section in
order to align access holes in backrest with
bolts holding the upper cylinder mount.
Remove bolts with extended socket, remove
mount.
g. The power section may now be hoisted
straight up sufficiently to allow the rollers on
the fork section to clear the channels on the
power section. Move the power section on
PTW1104
away from the fork section and place on
blocking.
h. Remove the four rollers (29, Figure 4-14) and
thrust bearings (30), noting thickness of
thrust bearings at each roller.
3. Fork Section Repair:
a. Inspect rollers (29, Figure 4-14) for wear, or
other damage. Replace defective roller if nec-
essary. Pack rollers with grease.
b. Inspect sleeve bushings (25) for wear or
other damage. Bushing must be replaced if
wall thickness is less than 1/16 inch. Press
new bushing into bore, flush with inside sur-
face of fork channel.
c. Inspect fork section (1) for broken welds and
weld as necessary. Replace fork section if
forks have been bent severely.
4. Power Section Frame Repair:
a. Repair of power section frame (11, Figure 4-
13) is limited to chasing damaged threads
and welding of any broken welds.
b. Replace a worn or damaged U-clip nuts (2).
c. Removal of components mounted on power
section frame may be necessary to effect
repairs/welding of frame, refer to table of con-
tents for identification of instructions on such
components.
4-19
5. Fork Section and Power Section Frame Assem-
bly:
NOTE: Prior to assembly of the fork section and
power section, check adjustment of the fork
pull rods, paragraph 4-6.3.. Frame Assembly:
Fork Section and Lift Linkage Repair and
Replacement.C1.p.
a. Install thrust bearings (30, Figure 4-14), as
noted during removal, and rollers (29). If nec-
essary, adjust the number/thickness of thrust
bearings used to shim fork section rollers for
proper fit into power section channels when a
new fork section is installed.
b. Brush entire length of roller channels in frame
(11, Figure 4-13) with grease (No. 2, Table 3-
4).
c. With hoist lift power section so that the chan-
nels are slightly above rollers on fork section.
Move the power section into the fork section
aligning rollers (29, Figure 4-14) with chan-
nels of power section frame. Carefully lower
power section, engaging rollers in channels
of power section frame.
d. Align access holes with bolt in top cylinder
mount.
e. With power section lowered sufficiently, posi-
tion hydraulic cylinder in socket of frame and
support cylinder with item 4, 5, 6 & 7 (4, Fig-
ure 4-29).
f. Raise power section sufficiently to engage
cylinder rod end in socket of fork frame.
g. Install hydraulic fittings in cylinders and con-
nect hydraulic lines.
h. Install cover (1, Figure 4-13).
i. Lower truck to floor, and install batteries
(Paragraph 4-7.).
j. Connect battery.
4-7. ELECTRICAL.
4-7.1. Battery Removal and Replacement (Figure
4-16).
Batteries are pulled out and lifted from battery com-
partment using the handles mounted on side of bat-
tery case.
WARNING: Batteries available for the lift truck vary in
weight. A suitable hoist and sling
arrangement must be used to prevent
injury or battery damage.
4-20
1. Disconnect the battery plug (2, Figure 4-16) from
the connector.
2. Grab battery handle at exposed side of batteries,
lifting slightly to clear retainer rod and pull battery
from side of power section frame.
3. Disconnect battery cables (2 and 6) from batter-
ies.
4-7.2. Battery Cable Assemblies Replacement.
1. Disconnect batteries (paragraph 4-7.1.).
2. Remove screw (3, Figure 4-16) and lockwasher
(4) to release battery cable assembly (2). Remove
clamp (5) from cable assembly.
3. Remove screws and nuts that secure connector
(handle) assembly (1) to connector on cable
assembly (2).
4. Note routing of cables.
5. Pull cables (2) up out of battery compartment.
6. Replace entire battery cable assembly (2 and 6) if
cables are damaged. Use a multimeter to verify
continuity.
7. Carefully route terminal end of cables (2) down
into battery compartment.
8. Position clamp (5) on cable assembly (2), allowing
sufficient cable length to plug cable connector to
receptacles of battery charger and contactor
panel and secure with lock washer (4) and screw
(3).
9. Connect battery cables (2 and 6) to batteries.
10. Connect battery plug (2) to TO DRIVE connector.
4-7.3. Resistor/Contactor Panel (Figure 4-17 &
Figure 4-18).
1. Contactor Panel Removal.
a. Disconnect the battery.
b. Remove screws (3, Figure 4-13), nuts (10),
lockwashers (4), flat washers (9), and motor
compartment (service) cover (1).
c. Refer to Figure 4-18 and tag and disconnect
all electrical wires and cables, which connect
to the contactor panel.
d. Remove two nuts (7, Figure 4-17) and lock-
washers (6) to release and remove the con-
tactor panel assembly and the speed control
resistor (11).
2. Contactor Panel Disassembly.
a. Carefully tag and disconnect all electrical
wires and cable assemblies, as shown on
Figure 4-18.
PTW1104
 R5315

Figure 4-16. Storage Batteries and Connectors

R5316

Figure 4-17. Electrical Installation - Resistor Trucks

PTW1104 4-21
 R5317

Figure 4-18. Contactor Panel Assembly - Resistor Trucks

4-22 PTW1104
 R5318

Figure 4-19. Electrical System Installation - Transistor Trucks

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

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

R5319

Figure 4-20. Contactor Panel Assembly - Transistor Trucks

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

R4133

Figure 4-21. Contactor Panel Assembly - Transistor Trucks

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

R5319

Figure 4-22. Contactor Panel Assembly - Transistor Trucks

4-26 PTW1104
 d. Remove nuts (7, Figure 4-19) and lockwash-
ers (6) to release and remove the contactor
panel assembly.
2. Contactor Panel Disassembly.
a. Refer to Figure 4-20 thru Figure 4-22 for loca-
tion and identity of component mounted on
the panel and remove defective part.
b. The forward and reverse contactors used on
this panel are not repairable and must be
replaced if defective.
3. Contactor Panel Reassembly.
a. Install replacement parts in same location
and orientation as removed defective part.
b. Connect all electrical wires and cable assem-
blies, as noted during removal and shown on
Figure 4-20 thru Figure 4-22.
4. Contactor Panel Installation.
a. Install contactor panel and secure with lock-
washers (6, Figure 4-19) and nuts (7).
b. Refer to Figure 4-20 thru Figure 4-22 and
connect all electrical wires and cables to the
contactor panel, as noted during removal.
c. Install motor compartment (service) cover (1,
Figure 4-13) and secure with flat washers (9),
lockwashers (4), nuts (10), and screws (3).
d. Connect the battery.
4-7.5. Horn Replacement.
To replace the horn, proceed as follows:
NOTE: The spike suppressor (4, Figure 4-23) is only
applicable to transistor units.
1. Perform steps 2a and 2b, above.
2. Tag and disconnect all electrical connections from
horn (5).
3. Remove nuts (1), lockwashers (2), and flat wash-
ers (3) to release and remove the horn (5).
4. If working with a transistor unit, check the spike
suppressor assembly (4) for damage. If any part
is damaged, the entire spike suppressor assem-
bly (4) must be replaced.
5. Install horn (5) and secure with nuts (1), flat wash-
ers (3), and lockwashers (2).
6. Connect all electrical wires to the horn, as noted
during removal.
PTW1104
7. Install motor compartment (service) cover (1, Fig-
ure 4-13) and secure with flat washers (9), lock-
washers (4), screws (3), and nuts (10).
8. Connect the battery.
4-7.6. Battery Charger (Figure 4-24).
The battery charger is mounted in the upper right side
of the power section frame under the top cover. The
plug-in connector is accessible through an opening in
the top cover, which also carries the charger ammeter.
All replaceable parts are shown in Figure 4-24.
4-7.7. Wire Harness Testing.
1. Wire harnesses are illustrated and identified on
the figures in this manual containing the compo-
nents they are associated with. As an aid to test-
ing, individual wires in each harness have their
wire numbers permanently marked on both ends.
Refer to the wiring diagram (Figure 4-25 for Resis-
tor Units. Figure 4-26 thru Figure 4-28 for Transis-
tor Units).
2. Testing procedures are as follows:
a. Disconnect the battery.
b. Tag and disconnect electrical wires as neces-
sary.
c. Disconnect plug(s) and/or receptacle(s), if
any.
d. Using a multimeter, check all individual wire
leads for continuity. Continuity must exist in
each individual wire lead.
3. If a wire harness fails continuity test, it must be
replaced. Make careful note of harness routing,
and location of any clamps or wire ties before
removing. Route new harness, and install any
clamps or wire ties, as noted during removal.
4. Connect electrical wires, as noted during removal.
5. Connect any plug(s) and/or receptacle(s), as
noted during removal.
6. Connect the battery.
4-7.8. Wiring.
Electrical wiring installation for resistor trucks is shown
on Figure 4-17 and Figure 4-18. Electrical wiring
installation for transistor trucks is shown on Figure 4-
19 thru Figure 4-22. When removing or installing elec-
trical wires or cables, refer to the wiring diagrams (Fig-
ure 4-25 for resistor trucks, Figure 4-26 thru Figure 4-
28 for transistor trucks), to help ensure proper installa-
tion.
4-27
 e. Refer to Figure 4-17 or Figure 4-19 and
remove clamps (5) from transmission and
underside of frame top-plate. Note position of
the different size hardware to help ensure
proper installation.
f. Remove wire ties as necessary to separate
cables. Disconnect control cable assembly
(3) at large connector, located at contactor
panel.
g. If removing the transmission, pull end of con-
trol cable up through opening on side of
transmission housing.

R5320

Figure 4-23. Horn Installation

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

4-28 PTW1104
 NOTES

PTW1104 4-29
 R5322

Figure 4-25. Wiring Diagram - Resistor Trucks

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

R5323

Figure 4-26. Wiring Diagram - Transistor Trucks

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

R4131-1

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

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

R4131-2

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

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

R6126

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

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

R6127

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

PTW1104 4-35
 R5324
Figure 4-29. Hydraulic System Installation
h. Inspect all electrical wires and cables for
damage. Using a multimeter, check suspect
wires for continuity.
i. Tag and disconnect a damaged wire or cable
and install replacement part in same location.
2. Installation.
a. If removed, feed end of electric control cable
through opening in side of transmission on
which bracket is mounted.
b. Connect all electrical wires and cables as
noted during removal and shown on Figure 4-
17 or Figure 4-19.
c. Secure cables to transmission housing and
power section frame with clamps and associ-
ated hardware. Use wire ties to bundle cables
and wires as noted during removal.
d. Pivot transmission through entire turning
range, observing that electrical cables and
wire leads will flex properly and not become
caught or pinched at any time.
4-36
e. Check operation of dead-man switch and
brake. Adjust as necessary (Paragraph 4-4.).
f. Install cover (1, Figure 4-13) and secure with
flat washers (9), lockwashers (4), nuts (10),
and screws (3).
g. Operate truck to ensure electrical connec-
tions were properly made.
h. Connect the battery.
4-8. HYDRAULICS.
4-8.1. Line and Fitting Replacement.
WARNING: When forks are raised, pressure exists in
the hydraulic system lines and fittings. To
ensure release of pressure, forks must
be fully lowered and the battery discon-
nected before performing any mainte-
nance on the hydraulic system.
PTW1104
 R4356
Figure 4-30. Pump, Motor and Reservoir Assembly
NOTE: Leaking hydraulic fittings may be remedied by
simply tightening fitting. If this does not rem-
edy the leak, the fitting or line must be
replaced.
1. Lower forks fully.
2. Remove battery (Paragraph 4-7.).
3. Remove screws (3, Figure 4-13), nuts (10), lock-
washers (4), flat washers (9), and motor compart-
ment (service) cover (1).
CAUTION: Hydraulic oil can damage parts. Wipe off
any oil immediately. Provide a container
under line or fitting, before disconnect-
ing.
4. Refer to Figure 4-29 and remove leaking line or
fitting and replace it with a new line or fitting.
5. Remove the vent plug (15, Figure 4-30), and
elbow (13). Check level of hydraulic oil. Hydraulic
oil must be one inch below bottom of elbow (13). If
PTW1104
required, add hydraulic oil to bring to proper level.
Use hydraulic oil listed in Table 3-4.
6. Reinstall the vent plug (15) and connect the bat-
tery.
7. Operate the lift lower buttons to refill cylinder and
lines with hydraulic oil.
8. Lower forks fully and disconnect battery.
9. Remove the vent plug (15) and elbow (13) and
recheck level of hydraulic oil. Hydraulic oil must be
one inch below bottom of elbow (13). If required,
add hydraulic oil to bring to proper level. Use
hydraulic oil listed in Table 3-4.
10. Reinstall vent plug.
11. Install motor compartment (service) cover (1, Fig-
ure 4-13) and secure with flat washers (9), lock-
washers (4), nuts (10), and screws (3).
12. Install the battery (Paragraph 4-7.).
4-37
 PACKING KIT
901498 CONTAINS:
ITEM QTY
1 1
2 1
4 1

R5325

Figure 4-31. Hydraulic System Installation

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

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

4-38 PTW1104
4-8.4. Lift Cylinder Repair.
To rebuild or replace components in a lift cylinder, pro-
ceed as follows:
1. Secure the lift cylinder in a vise, clamping lightly
at the base of the cylinder.
2. With spanner wrench, remove the cylinder head
(3, Figure 4-31) from the cylinder weldment (6).
3. Withdraw the cylinder rod (5) from the cylinder.
NOTE: If the, cylinder weldment (6), cylinder rod (5),
or cylinder head (3) is damaged, the entire lift
cylinder must be replaced.
4. Replace all wipers, seals and damaged or worn
parts.
5. Coating all parts with hydraulic oil (Table 3-4).
6. Insert cylinder rod (5), with attached parts, into
cylinder weldment (6).
7. Install cylinder head and tighten to 5-7 lbs/ft.
4-8.5. Hydraulic Pressure Adjustment.
The relief valve is factory set to open at the rated pres-
sure setting for the pump (not to exceed 2575 psi) and
rarely needs adjusting. If you suspect that the relief
valve is malfunctioning, perform the following proce-
dures:
1. Lower forks as far as they will go.
2. Remove screws (3, Figure 4-13), nuts (10), lock-
washers (4), flat washers (9), and motor compart-
ment (service) cover (1).
3. Disconnect hose (8, Figure 4-29) from elbow at
pump and connect a pressure gauge of adequate
range (0-3000 psi) to the elbow.
PTW1104
4. Activate pump motor and observe reading on
pressure gauge. If pressure reading is between
2475 and 2575 psi, the relief valve is functioning
properly and does not need adjustment. If pres-
sure reading is below 2475 psi or above 2575 psi,
proceed as follows to adjust relief valve:
CAUTION: Do not set pressure too high or hydraulic
system may be damaged. Factory rec-
ommended limits of 2475 to 2575 psi
should be observed. Under no circum-
stances should pressure be set above
2575 psi.
5. With pump motor running, observe pressure
gauge and set pressure between 2475 and 2575
psi by turning adjusting screw (14, Figure 4-30)
clockwise to increase pressure or counterclock-
wise to decrease pressure.
6. Deactivate pump motor, disconnect pressure
gauge, and reconnect hose.
7. Install motor compartment (service) cover (1, Fig-
ure 4-13) and secure with flat washers (9), lock-
washers (4), nuts (10), and screws (3).
4-9. DECALS AND TRIM.
4-9.1. Painting Requirements.
Clean all dirt, scale, and other foreign matter from sur-
faces to be painted. Touch up paint on frames and pull
rods with yellow enamel (901201). Touch up paint on
remaining parts with black satin enamel (901202).
4-9.2. Decals and Plates.
Refer to Figure 1-1 for location and identification of
decals and information plates. Make sure decals and
plates are legible and securely attached.
4-39
 NOTES

4-40 PTW1104
 SECTION 5
OPTIONS
5-1. BATTERY DISCHARGE INDICATOR.
Replacement parts for the optional battery discharge
indicator are detailed in Figure 7-24. Refer to the wir-
ing diagram (Figure 4-25 for resistor trucks. Figure 4-
26 thru Figure 4-28 for transistor trucks.) to help
ensure proper connections.
5-1.1. Battery Discharge Indicator Replacement.
1. Operation of the battery discharge indicator (1,
Figure 7-24) may be checked by comparing its
reading against a hydrometer. Indicator should
show a full charge when hydrometer shows a spe-
cific gravity of 1.260 to 1.275.
2. To replace the battery discharge indicator (1), pro-
ceed as follows:
a. Disconnect the battery.
b. Remove screws (6, Figure 4-13), lockwash-
ers (4), flat washers (7), and right hand cover
(8).
c. Tag and disconnect terminals (2, Figure 7-
24).
d. Remove two knurled nuts and U-bracket, part
of battery discharge indicator (1), to release
and remove the indicator.
NOTE: Replacement indicator will be furnished with
nuts and U-bracket. The original U-bracket
may be reused, if not damaged.
e. Install battery discharge indicator (1) and
secure with supplied U-bracket and nuts. If
required, trim the U-bracket legs to proper
length.
f. Connect terminals (2), as noted during
removal.
g. Install right hand cover (8, Figure 4-13) and
secure with flat washers (7), lockwashers (4),
and screws (6).
h. Connect the battery.
5-2. HOURMETER.
The hourmeter is available for attachment to the motor
circuits to indicate use of the drive and lift functions.
Refer to Figure 7-27 for replacement parts. Refer to
the wiring diagram (Figure 4-25 for resistor trucks. Fig-
ure 4-26 thru Figure 4-28 for transistor trucks.) to help
ensure proper connections.
PTW1104
5-2.1. Hourmeter Replacement.
1. Operation of the hourmeter (3, Figure 7-27) may
be checked against a watch.
2. To replace the hourmeter (3), proceed as follows:
a. Disconnect the battery.
b. Remove screws (6, Figure 4-13), lockwash-
ers (4), flat washers (7), and right hand cover
(8).
c. Tag and disconnect terminals from hourmeter
(3, Figure 7-27).
d. Remove nuts (10), lockwashers (9), and
screws (2) to release and remove hourmeter
(3), diode assembly (8), and insulating pad
(7).
e. Install hourmeter (3), insulating pad (7), and
diode assembly (8), and secure with screws
(2), lockwashers (9), and nuts (10).
f. Connect terminals to hourmeter (3).
g. Install right hand cover (8, Figure 4-13) and
secure with flat washers (7), lockwashers (4),
and screws (6).
h. Connect the battery.
5-3. KEYSWITCH.
The optional keyswitch is shown in Figure 7-25. The
keyswitch installation is accomplished by inserting the
supplied wiring into wire number 3, of control panel
harness, at the slip-on connector of the in-line fuse.
Refer to the wiring diagram (Figure 4-25 for resistor
trucks. Figure 4-26 thru Figure 4-28 for transistor
trucks) to help ensure proper connections.
5-4. COLD CONDITIONING PACKAGE.
Continuous operation of the PTW lift trucks at temper-
atures below 32° F (freezing) in applications such as
meat lockers and freezers, requires the changing of
oils and grease, and modification of the control head
and deadman switch as shown in Figure 7-26. For
intermittent operation under 32° F, the oils and grease
need not be changed. Refer to the wiring diagram (Fig-
ure 4-25 for resistor trucks. Figure 4-26 thru Figure 4-
28 for transistor trucks) to help ensure proper connec-
tions.
5-1
5-5. LOAD BACKREST. 5-6. CASTER
A load backrest is available for addition to the lift truck Casters are available for additional stability. Identifica-
to allow handling of high loads. Identification of tion of replacement parts are shown in Figure 7-29.
replacement parts, are shown in Figure 7-28.

5-2 PTW1104

6-1. TROUBLESHOOTING CHART.
MALFUNCTION
Truck will not run, lift system
does not operate.
Truck does not run forward or
reverse. All other functions
operate normally.
Truck runs forward but not in
reverse.
Truck runs in reverse but not
in forward.
Truck runs forward and in
reverse at lower speeds; will
not run at high speed.
Truck runs forward and
reverse at second or third
speed only. Truck does not
move when control is in first
speed position. All else is nor-
mal.
PTW1104
SECTION 6
TROUBLESHOOTING
PROBABLE CAUSE
a. 300 AMP fuse blown
b. Battery dead or disconnected.
c. Defective wiring.
d. Keyswitch, if equipped, defec-
tive.
a. Check all wiring. A loose con-
nection may be the cause of
malfunction.
b. Defective deadman brake
switch.
c. Switch in control head broken.
Defective switch in control head,
or defective contactor.
Defective switch in control head,
or defective contactor.
Defective speed control switch in
control head, or defective by-pass
contactor.
a. Resistor Trucks: Defective or
open speed control resistor.
b. Transistor Trucks: Defective
transistor control.
CORRECTIVE ACTION
Check fuse (Figure 4-18 for Resistor Units.
Figure 4-20 thru Figure 4-22 for Transistor
Units.) Replace if necessary
Check battery and quick disconnect (Fig-
ure 4-16)
Check for open circuit and repair as
required.
Bypass keyswitch to determine if bad.
Tighten all loose connections before fur-
ther troubleshooting
Check and replace switch if defective.
Check and replace switch if defective.
Check for positive dc voltage at number 2-
wire on reverse contactor. If not present
when steering arm is in operating position
and control lever is in reverse, reverse
switch is defective. If voltage is present,
contactor is defective.
Check for positive dc voltage at number 1-
wire on forward contactor. If not present
when steering arm is in operating position
and control lever switch is in forward, for-
ward switch is defective. If voltage is
present, contactor is defective.
Check for positive dc voltage at number 5-
wire on by-pass contactor. If not present
when steering arm is in operating position
and control lever is in full speed reverse,
speed control switch is defective. If voltage
is present, contactor is defective.
Check for clean, tight connection. Check
for continuity and replace as required.
Replace transistor control.
6-1
 MALFUNCTION
Mechanical brake grabs when
steering arm is in operating
position.
Oil sprays or flows from top of
a lift cylinder.
Squealing sounds when lifting
forks.
Lift carriage does not lift to
top.
Weak, slow or uneven action
of hydraulic system.
Forks do not lift, motor does
not run.
Forks do not lift, motor runs.
Forks lift, but will not go down.
Load will not hold.
Forks creep downward under
load when in a raised position.
Steering arm does not return
to the upright position.
6-2
PROBABLE CAUSE
Brake linkage overadjusted.
Defective packing in lift cylinder.
a. Oil level too low.
b. Dry channels in mast.
c. Defective carriage bearing.
Oil level too low.
a. Defective pump or relief valve.
b. Worn lift cylinder packing.
c. Load larger than capacity.
d. Defective lift motor solenoid.
e. Battery charge low.
a. Battery is dead or discon-
nected.
b. Defective wiring.
c. Defect in electrical system for
operating pump motor.
Defect in hydraulic system.
Defect in hydraulic system.
a. Oil bypassing internally
between check valve and
adapter body.
b. Worn lift cylinder packing.
Leak in hydraulic system cylinder
packing or lowering valve.
a. Return spring improperly
adjusted.
b. Binding brake linkage or elec-
trical cable.
CORRECTIVE ACTION
Adjust brake.
Overhaul lift cylinder and install new pack-
ing, seal, and wiper ring.
Add oil to reservoir.
Apply grease.
Replace bearing.
Add oil to reservoir.
Check pressure. Adjust valve.
Repack cylinder.
Refer to I.D. plate for capacity.
Replace.
Charge battery.
Check and recharge if required.
Check and repair as required.
Check lift switch in control head, as well as
the solenoid on the motor. Repair or
replace.
Check the oil level in the reservoir and the
oil lines to the lift cylinders, and repair as
required.
If normal, check the hydraulic pump, and
relief valve. Repair, or adjust.
Check lowering control switch and lower-
ing valve; look for blockage in hydraulic
line. Repair/adjust as required.
Disassemble, clean, and reassemble.
Replace worn parts as required.
Replace cylinder packing.
Check lowering solenoid valve and internal
check valve for blockage preventing valve
from closing completely to block oil. Look
for leaking fitting in hydraulic line. Check
pump for leakage back into reservoir.
Repair or replace as required.
Readjust spring tension.
Check and free the binding item.
PTW1104
 MALFUNCTION
Truck moves forward when
arm is pulled down.
Steering arm jerks exces-
sively starting or stopping the
truck.
Drive motor is jerky.
PROBABLE CAUSE
a. Belly-button switch defective.
b. Short in control head.
a. Worn steering arm pivot bush-
ings.
b. Drive wheel worn.
Motor commutator damaged.
CORRECTIVE ACTION
Check for short, and repair or replace as
necessary.
Check wiring and repair as required.
Replace bushings if difference between ID
of pivot bushings (5, Figure 4-9) and OD of
pivot tube (7) exceeds 1/32 inch.
Replace drive wheel if worn to within 3/8
inch of hub.
Replace motor.

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

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

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

PTW1104 6-3
 R5326

Figure 6-1. Contactor Testing

6-4 PTW1104
 R5327

Figure 6-2. Switch Testing

PTW1104 6-5
6-3. TRANSISTOR CONTROLLER TROUBLE-
SHOOTING.
Refer to wiring diagrams included in SECTION 4 for
complete wiring diagram for this truck. Refer to these
diagrams and the schematic for tracing of electrical cir-
cuits during troubleshooting and testing procedures.
6-3.1. Circuit Operation.
While operation of the transistorized control system is
transparent to the operator, it is helpful to understand
the operating principles and features of the transistor
controller when troubleshooting trucks equipped with
this controller. The controller is mounted on the con-
tactor electrical panel, installed within the main hous-
ing of the lift truck. Figure 6-3 identifies the contacts of
a typical controller.
1. Smooth stepless operation.
The Big Joe custom transistor controller allows
superior operator control of the vehicle's drive
motor speed. The amount of current delivered to
the motor is set by varying the "on" time (duty
cycle) of the controller's MOSFET transistors.
This technique, called "pulse width modulation"
(PWM), permits silent, stepless operation.
2. Current multiplication
During acceleration and during reduced speed
operation, the controller allows more current to
flow into the motor than flows out of the battery.
The controller acts like a dc transformer, taking in
low current and high voltage (the full battery volt-
age) and putting out high current and low voltage.
The battery only has to supply a fraction of the
current that would be required by a conventional
controller (in which the battery current and motor
current are always equal). The current multiplica-
tion feature gives vehicles using these controllers
dramatically greater driving range per battery
charge.
3. Acceleration limiting
A built-in acceleration limiting circuit maintains a
maximum rate of power increase to the motor. If
full throttle is applied at start-up, the acceleration
ramp setting determines how quickly the output of
the controller increases. The standard setting is
such that with full throttle applied, the controller
requires approximately one second to reach full
output. This feature contributes to smooth, gentle
6-6
starts. (See adjustment instructions to adjust
acceleration ramp setting.)
4. Current limiting
The transistor controllers limit the motor current to
a preset maximum. This feature protects the con-
troller from damage that might result if the current
were limited only by the motor demand. The cur-
rent limit feature also protects the rest of the sys-
tem. By eliminating high current surges during
vehicle acceleration, the stresses on the motor
and batteries are reduced and their efficiency and
service life are improved. Similarly, there is less
wear and tear on the vehicle drivetrain, as well as
on the ground on which the vehicle rides (an
important consideration with golf courses and ten-
nis courts, for example).
The maximum motor current can be factory-set to
a lower value than the standard maximum if
requested. For further flexibility, the current limit
setting on some models is field-adjustable. (See
adjustment instructions.)
5. Plugging
A form of electrical braking called plugging can be
used to slow the vehicle. When the motor is
reversed with the accelerator advanced (i.e.,
when the vehicle is moving), the armature acts as
a generator. current from the armature flows
through a plug diode in the controller. The control-
ler regulates the current in the motor field winding
to give an appropriate level of plugging torque.
The vehicle slows smoothly to a stop, then auto-
matically accelerates in the other direction. A
1 kHz tone may be heard during plugging. The
maximum plugging current is factory set per cus-
tomer requirements, and is also field adjustable
(see adjustment instructions).
6. Undervoltage protection
The control circuitry requires a minimum battery
voltage to function properly. The controller is
therefore designed so its output is gradually
reduced if the battery voltage falls below a certain
level; the cutoff voltage for the various models is
listed in the specifications (See Table 6-1 and
Table 6-2). Reducing the output to the motor
allows the battery voltage to recover, and an equi-
librium is established in which the battery supplies
as much current as it can without falling below the
cutoff voltage.
PTW1104
 Table 6-1. Controller Specifications Table 6-2. Controller Specifications
Prior To Serial Number 373234 Serial Number 373234 to 376836
Big Joe Model 005467-01 005467-02 Big Joe Model 907200-02
Input Voltage 12 24-36 Input Voltage 24
Current Limit 400 Amps* 400 Amps* Current Limit 250 Amps*
Rating: Rating:
2 Minute 300 Amps 300 Amps 1 Minute 250 Amps
5 Minute 210 Amps 210 Amps 2 Minute 200 Amps
1 Hour 135 Amps 135 Amps 5 Minute 150 Amps
Voltage Drop @ 100 Amps 0.25 V 0.25 V 1 Hour 100 Amps

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

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

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

Standby Current mA mA Operating Frequency 15 kHz

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

+10% +10%
* 30 Second rating.

Figure 6-3. Full Feature Electronic Motor Controller

PTW1104 6-7
7. Overvoltage protection
Similarly, the controller has a means of preventing
operation when battery voltages are too high for
proper functioning. Excess voltage can occur from
an unregulated battery charger or from improper
or faulty wiring.
8. Thermal protection
Because they are well designed thermally, the
controllers barely get warm in normal operation.
Overheating can occur, however, if the controller
is undersized for its application or otherwise over-
loaded. If the internal temperature of the controller
exceeds 165°F, the current limit drops off steadily
until it is reduced to zero at 200°F. This allows the
vehicle to be operated at a reduced performance
level in order to permit maneuvering out of the
way and stopping in a good place. After the con-
troller cools down, full current limit and perfor-
mance return automatically. Although this action
is not damaging to the controller, it does suggest
a mismatch. If thermal cutback occurs often in
normal vehicle operation, the controller is proba-
bly undersized for the application, and a higher
current model should be used. The controller
shifts frequency during overtemperature from its
normal 15 kHz to 1 kHz, providing an audible tone
alerting the operator to the overtemperature con-
dition.
The controller is also protected from undertem-
perature. Should its internal temperature fall
below -25°C (from being parked overnight in an
icehouse, for example), the current limit will be 1/3
the maximum. Once the controller warms above
-25°C, full current limit and performance return
automatically.
9. Accelerator fault protection (runaway
protection)
To prevent uncontrolled operation the controller
shuts off the motor output in the event of a short
circuit fault in the accelerator or its wiring. The
throttle configuration is a 2-wire potentiometer
ranging from 5000 ohms for full off to 0 ohms for
full on. The controller returns to normal operation
when the fault (e.g., accelerator wiring, broken
connectors, potentiometers that fail or are set to
start at 0) has been corrected.
6-8
10. Controller fault protection (Prior to Serial
Number 373234)
Faults can be caused internally (e.g., shorted
transistors) or externally (e.g., wrench or hard-
ware dropped across controller terminals). While
disabled, the controller's direction contactor out-
put and internal logic are both off.
Faults are detected by monitoring the controller's
M-output. If M-remains low for more than 20 ms, a
fault is detected. Fault protection is disabled for
throttle demand greater than 80%
To recover from a fault, the F/R switch must be
turned off and back on again. If the fault has been
corrected, the controller will turn back on.
11. Fault Detection (Serial Number 373234 To
376836)
An internal microcontroller automatically main-
tains surveillance over the functioning of the con-
troller. When a fault is detected, the appropriate
fault code is signaled via the LED, externally visi-
ble on the side of controller (See Figure 7-23 for
LED location on controller). The diagnostic codes
flashed by the LED are listed in Table 6-4.
If the fault is critical, the controller is disabled.
More typically, the fault is a remediable condition -
for example, an undervoltage fault is cleared
when the condition is removed.
The automatic fault detection system includes:
contactor coil open / shorted driver (F/R and
shunt contractor)
contactor driver overcurrent / contactor coil
short
contactor welded
emergency reverse circuit check
M- output fault
memory checks upon start-up
overvoltage cutback
power supply out of range (internal)
throttle fault
undervoltage cutback
watchdog (external and internal)
PTW1104
 a. Hand Held Programmer.
A hand held programmer is available that is
designed specifically for use with the control-
ler. It serves dual functions of reading diag-
nostic data provided by the controller and
adjusting certain performance values of the
controller. The programmer (Part Number
005472-02) is available through your Big Joe
dealer. If you require dealer location informa-
tion contact Big Joe Manufacturing Co.
phone number 847-298-9800.
b. Fault Recording.
Fault events are recorded in the controller's
memory. Multiple occurrences of the same
fault are recorded as one occurrence.
The fault event list can be loaded into the pro-
grammer for readout. The Special Diagnos-
tics mode provides access to the controller's
diagnostic history file - the entire fault event
list created since the diagnostic history file
was last cleared. The Diagnostics mode, on
the other hand, provides information about
only the currently active faults.
c. Fault Recovery (including recovery from
disable).
Almost all faults require a cycling of the KSI
or brake input to reset the controller and
enable operation. The only exceptions are
shown in Table 6-3.
12. Weather resistance
All controllers are housed in rugged epoxy-
sealed, anodized aluminum extrusions that pro-
vide excellent environmental protection.
13. Emergency reverse: enhanced plugging
current
Emergency reverse (or "belly button") switches
can be mounted on the handles of walkie vehi-
cles. The emergency reverse switch is wired to
the controller and other vehicle electronics in such
a way that if the button is pressed against the
operator by the advancing vehicle, the controller
enables enhanced plugging current to stop the
vehicle quickly and revere its direction.
PTW1104
Table 6-3. Fault Recovery Exceptions.
FAULT RECOVERY
anti-tiedown release and re-select Mode 1
contactor overcurrent when condition clears
emergency reverse BB re-applied or brake cycled
HPD lower throttle to below HPD threshold
overvoltage when battery voltage drops below over-
voltage
SRO when proper sequence is followed
thermal cutback when temperature comes within range
throttle fault clears when condition gone
undervoltage when battery voltage rises above under-
voltage
14. Arcless F/R and bypass contactor switching
Each time the F/R switch passes through neutral,
the controller's output is rapidly turned off (even if
the throttle is held on) so that all motor current
has stopped by the time the direction contactor
drops out. Controller output always starts at zero
and increases smoothly at the set acceleration
rate each time a new direction is selected. Bypass
contactor operation is also arcless, when inter-
rupting currents less than the controller's current
limit.
15. High pedal disable (HPD)
When the controller (KSI) is turned on, it will
sense a “high” (advanced accelerator and will
inhibit the output until the accelerator is released
and reapplied. By preventing the unit KSI from
being turned on with the throttle depressed, this
safety feature (also called Neutral Start) required
the truck to start smoothly from zero throttle when
the battery is plugged in. It also protects against
sudden starts caused when problems in the throt-
tle linkage (e.g., bent parts, broken return sprint)
give a partial or full throttle signal to the controller
even with the accelerator released when the bat-
tery is plugged in.
6-3.2. General Checkout (Serial Number 373234 To
376836).
Carefully complete the following checkout procedure. If
you find a problem during the checkout, refer to Para-
graph 6-3.4. for further information.
The checkout can be conducted with or without the
handheld programmer (See Paragraph a.). The check-
out procedure is easier with a programmer. Otherwise,
observe LED for codes.
6-9
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 that
the brake is applied (brake switch open),
the throttle is in neutral, and the forward/
reverse switches are open.
Do not stand, or allow anyone else to
stand, directly in front of or behind the
vehicle during the tests.
1. If a programmer is available, connect it to the pro-
grammer connector.
2. Turn the keyswitch on. The programmer should
"power up" with an initial display, and the control-
ler's Status LED should begin steadily blinking a
single flash. If neither happens, check for continu-
ity in the keyswitch circuit and controller ground.
3. If you are using a programmer, put it into the diag-
nostic mode by pressing the "DIAGNOSTICS"
key. The display should indicate "No Known
Faults."
Release the brake by pulling down the control arm
into the operating position. The LED should con-
tinue blinking a single flash and the programmer
should continue to indicate no faults. If there is a
problem, the LED will flash a diagnostic code and
the programmer will display a diagnostic mes-
sage. If you are conducting the checkout without a
programmer, look up the LED diagnostic code in
Table 6-4.
When the problem has been corrected, it may be
necessary to cycle the brake in order to clear the
fault code.
4. With the brake released, select a direction and
operate the throttle. The motor should begin to
turn in the selected direction. If it does not, verify
the wiring to the forward/reverse switches, for-
ward/reverse contactors, and motor. The motor
should run proportionally faster with increasing
throttle. If not, refer to Paragraph 6-3.4.
5. If you are using a programmer, put it into the test
mode by pressing the "TEST" key. Scroll down to
observe the status of the forward, reverse, brake,
emergency reverse, and mode switches. Cycle
each switch in turn, observing the programmer.
6-10
Each input should show the correct state on the
programmer.
6. Check the controller's fault detection circuitry as
described in paragraph 6-3.10.
7. Take the vehicle off the blocks and drive it in a
clear area. It should have smooth acceleration
and good top speed.
8. Test the plug braking of the vehicle. Verify that the
plug braking option is as desired (variable or
fixed).
9. Verify that all options, such as high pedal disable
(HPD), static return to off (SRO), and anti-
tiedown, are as desired.
10. Check to see whether the emergency reverse
(belly button) feature is working correctly. Verify
that the circuit is operational by momentarily dis-
connecting one of the emergency reverse wires.
The vehicle should be disabled and a fault indi-
cated.
6-3.3. Troubleshooting (Prior To Serial Number
373234).
The following procedures are to fix vehicles that don't
operate properly. Refer to wiring diagrams included in
SECTION 4 when conducting these tests. Make sure
the controller is hooked up as shown in Figure 6-3.
Refer to the wiring diagram and schematic for your
vehicle. These tests require a general purpose volt
ohmmeter; you can use either a conventional "V-O-M"
or an inexpensive digital voltmeter.
In general, when a problem has been isolated to the
controller, remove and replace it. If the source of the
problem has not been determined or is suspected to
be within the truck (not the controller), proceed as
directed.
NOTE: Working on electric vehicles poses some
dangers. You must protect yourself against
runaways, high current arcs, and outgassing
from lead acid batteries:
Runaways - Some fault conditions could
cause the vehicle to run out of control. We
suggest that you jack up the vehicle and get
the drive wheels off the ground before
attempting these procedures or any other
work on the motor control circuitry.
High current arcs - electric vehicle batteries
can supply very high power for short times. if
PTW1104
 they are accidentally short circuited, arcs can
occur. Always open the battery circuit before
doing work on the motor control circuit. Wear
safety glasses and use properly insulated
wrenches to prevent accidental shorts.
Lead acid batteries - Charging or discharg-
ing batteries generates hydrogen gas, which
can build up in and around the batteries.
Always follow the battery manufacturer's rec-
ommendations when working around batter-
ies. Wear safety glasses.
1. Check for Power to the Controller
a. Leave the keyswitch off for these tests (if
truck is so equipped).
b. Verify that battery (-) connects to the B- ter-
minal of the controller. connect voltmeter (-)
lead to this point.
3.
c. Connect voltmeter (+) to the battery side of
the power fuse. Check for full battery voltage.
If it is not there, the trouble is in the battery
pack or the cables to it.
d. Connect the voltmeter (+) lead to the control-
ler B+ terminal. You should read full battery
voltage. If this voltage is zero or close to zero,
the trouble is either a bad controller, a bad
power fuse, or an incorrectly connected
cable. Trace the cable to make sure it is
hooked up right. If these check out, the con-
troller is malfunctioning.
2. Check for Contactor Operation and Keyswitch
Input (KSI)
a. Turn the key on and move the accelerator in
forward or reverse, until the microswitch oper-
ates.
b. This should cause the main contactor to
operate with an audible click. Connect the
voltmeter across the contactor coil terminal.
You should see full battery voltage.
c. The controller KSI terminal (top push on)
should also be getting full battery voltage.
Verify this with the voltmeter. Connect the
voltmeter (-) to the controller B- terminal, and
the voltmeter (+) to the controller's KSI termi-
nal.
d. If the contactor and KSI terminal are not get-
ting voltage, that's the problem. Use the volt-
meter to find out where it is not getting
through. Connect the voltmeter (-) to the con-
PTW1104
troller's B- terminal and check the following
points with the voltmeter (+) lead to trace the
flow:
(1) First, check both sides of the control wir-
ing fuse.
(2) Check both sides of the keyswitch (if
truck is so equipped).
(3) Check both sides of the accelerator
microswitch.
(4) Finally, check the contactor coil and con-
troller KSI.
e. If the contactor coil and KSI are getting volt-
age, make sure that the contactor is really
working, by connecting the voltmeter across
its big terminals. There should be no measur-
able voltage drop. If you see any at all, the
contactor is bad.
Check Potentiometer Circuitry
The following procedure applies to the basic
accelerator input configuration for these control-
lers, which is a nominal 5000 ohm potentiometer
connected as a two-wire rheostat (0 ohms = full
on, 5000 ohms = full off). Some controllers are
sold with other input characteristics. If your instal-
lation used one of these optional inputs, find out
what its range is and use a procedure comparable
to the one blow to make sure your accelerator is
working correctly.
a. With the forks lowered, the keyswitch off, and
the battery disconnected, pull off the connec-
tors going to the accelerator inputs of the
controller. connect an ohmmeter to the two
wires and measure the resistance as you
move the accelerator. The resistance at the
limits should be within these ranges:
Accelerator at Start: 4300 ohms to 4800
ohms
Accelerator at Maximum: 0 ohms to 50 ohms
b. If these resistances are wrong, it is because
the potentiometer itself is faulty or out of
adjustment, the wires to the pot are broken or
misconnected, the linkage is not moving the
pot shaft through its proper travel or a switch,
resistor, or the relay is defective or incorrectly
wired. (See wiring diagram.)
c. While you have the accelerator wires off the
controller, use an ohmmeter to check for
shorts between these wires and the vehicle
6-11
 frame. You should see a resistance of at least
10,000 ohms. If it is lower than that, inspect
the wiring for damaged insulation or contact
with the frame. If necessary, replace the
potentiometer.
d. Push the wires back on the controller termi-
nals.
e. Inspect the terminal area of the controller
closely. Occasionally a build-up of dirt or acid
residue of a conductive nature may cause
electrical leakage between the accelerator
input terminals and the B- or M- terminals,
leading to faulty accelerator operation. To
check for this problem, measure the voltage
at the upper pot terminal (by connecting the
voltmeter (-) lead to the controller's B- termi-
nal). The keyswitch must be on and a direc-
tional switch engaged for this test.
Lower Terminal
Accelerator at Start: 2.7 volts
Accelerator at Maximum: 7.0 volts
Compare your readings with these; if they are
different by more than a few tenths of a volt,
contamination is probably the trouble.
f. Carefully clean off the terminal area of the
controller with a cotton swab or clean rag
moistened with water, and dry thoroughly.
Now test the controller to see if proper opera-
tion is restored. If so, you should take steps
to prevent this from happening again. You
must keep dirt and water from reaching the
terminal area of the controller.
4. Check for controller output
a. Disconnect the wire from the direction con-
tactors to the F/R contactor output of the con-
troller.
b. Connect the voltmeter (+) lead to the control-
ler's B+ terminal. Connect the voltmeter (-)
lead to the controller's M- terminal.
c. Connect the battery, turn on the keyswitch,
move the accelerator in forward, and watch
the voltmeter as you advance the accelerator.
The voltmeter should read zero with the
accelerator released, and should read full
battery voltage with the accelerator at maxi-
mum. If it does not, the controller is bad and
must be replaced. If the voltmeter readings
6-12
are appropriate, release the accelerator, turn
off the keyswitch, disconnect the battery, and
reconnect the wire to the direction contac-
tors.
d. The next step is to measure the current in the
controller's M- lead. If you have a means of
measuring this high dc current, such as a
shut/meter setup or a clamp-on dc ammeter,
use it. If not, we recommend that you buy an
ammeter of the type that is simply held
against the wire being tested. these are avail-
able for a low cost at auto parts stores.
though the accuracy of these meters is not
great, they are adequate for this test.
e. Connect the battery, turn the keyswitch on,
move the accelerator in either forward or
revere, and watch the ammeter while advanc-
ing the accelerator.
f. If you see no current flowing in the M- lead,
the problem is an open circuit in the motor or
the wiring between the motor and the control-
ler. Check the F/R switch. If your vehicle uses
contactors for reversing, check to see that
they are operating and that their contacts are
closing. If these are okay, check the motor
armature and field for opens.
g. If you do see a high current flowing in the M-
lead, but the motor does not turn, the prob-
lem is either a short in the motor circuit, a
miswired motor, or a short in the controller's
internal plug diode. Test the plug diode as fol-
lows:
(1) Remove power by opening the battery
circuit. Take the cable off the controller's
A2 terminal.
(2) Use an ohmmeter to check the resis-
tance between the controller's A2 and B+
terminals. You are testing for the pres-
ence of a diode inside the controller, so
swap the two leads of the ohmmeter and
look for a low resistance one way and a
much higher one the other way. If your
meter has a diode test function, use it.
(3) If you find the diode to be shorted, the
controller is bad and needs to be
replaced.
h. Put the A2 cable back on the controller.
i. If the plug diode is OK, there is a short in the
motor circuit. An ordinary ohmmeter will not
work to find the short, because the resis-
PTW1104
 tances of the motor windings are so low. Test
the motor separately if it is suspected of hav-
ing a shorted winding.
j. Verify all illustrated connections and compo-
nentry (Chapter 4) within the truck. If all
check out and the source of the problem still
has not been found, replace the controller.
6-3.4. Diagnostics And Troubleshooting
(Serial Number 373234 To 376836).
The controllers provide diagnostics information to
assist in troubleshooting drive system problems. The
diagnostics information can be obtained in two ways:
reading the appropriate display on the programmer or
observing the fault codes issued by the Status LED.
The Status LED is located on side of the controller
(See Figure 7-23 for location of LED on controller).
Table 6-4. LED Codes
1. LED Diagnostics
During normal operation, with no faults present,
the Status LED flashes a single flash at approxi-
mately 1 flash/second. If the controller detects a
fault, a 2-digit fault identification code is flashed
continuously until the fault is corrected. For exam-
ple, code "3,2" - welded direction contactor -
appears as:
ooo oo ooo oo ooo oo
(3,2) (3,2) (3,2)
The codes are listed in Table 6-4. For suggestions
about possible causes of the various faults, refer to
Table 5. Troubleshooting Chart.
Operational faults - such as overtemperature - are
cleared as soon as operation is brought within range.
Non-operational faults - such as a throttle fault - usu-
ally require the brake or keyswitch to be cycled after
the problem is remedied.

LED CODE EXPLANATION

LED Off no power or defective controller

Solid On defective controller

Single Flash o controller operational; no faults

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

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

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

LED CODE PROGRAMMER EXPLANATION POSSIBLE CAUSE

LCD DISPLAY
1-2 HW FAILSAFE hardware fail-safe error 1. Controller defective
1,3 M- SHORTED M- output shorted 1. M- output shorted to ground.
2. Direction contactor not closing.
3. Direction contactor not closing fast enough.
4. Internal motor short to ground.
1,4 SRO SRO Fault 1. Improper sequence of KSI, brake, and direction inputs.
2. Wrong SRO type selected.
3. Brake or direction switch circuit open.
4. Sequencing delay too short.
2,1 THROTTLE FAULT 1 5kΩ-0 or wiper fault 1. Throttle input wire open.
2. Throttle input wire shorted to ground or B+
3. Throttle pot defective.
4. Wrong throttle type selected.
2,2 BB WIRING CHECK emergency reverse wiring fault 1. BB wire open.
2. BB check wire open.
2,3 HPD HPD sequencing fault 1. Improper seq. of KSI, brake, throttle inputs
2. Wrong HPD type selected.
3. Misadjusted throttle pot.
2,4 THROTTLE FAULT 2 Pot Low broken or shorted 1. Pot Low wire open.
2. Pot Low wire shorted.
3. Wrong throttle type selected.

6-14 PTW1104
 Table 6-5. Troubleshooting Chart (Continued)

LED CODE PROGRAMMER EXPLANATION POSSIBLE CAUSE

LCD DISPLAY
3,1 CONT DRVR OC driver output overcurrent 1. Direction contactor coil shorted.
2. Shunt field shorted.
3,2 DIR CONT WELDED welded direction contactor 1. Direction contactor stuck closed.
3,4 MISSING CONTACTOR missing contactor or shunt 1. Direction contactor coil open.
2. Direction contactor coil missing.
3. Shunt field open.
4. Wire to shunt or direction contactor open.
4,1 LOW BATTERY VOLTAGE low battery voltage 1. Battery voltage <16 volts.
2. Corroded battery or controller terminal.
3. Loose battery or controller terminal.
4,2 OVERVOLTAGE overvoltage 1. Battery voltage >33V
2. Vehicle operating with charger attached.
4,3 THERMAL CUTBACK over-/under-temp. cutback 1. Temperature >85°C or <-25°C.
2. Excessive load on vehicle.
3. Improper mounting of controller.
4. Operation in extreme environments.

6-3.5. Adjustment of Controller Potentiometers

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

NOTE: Stop the truck and release the handle during

adjustment.

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

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

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

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

PTW1104 6-15
 Table 6-6. Adjustment Settings
Function Setting
Creep Speed 7 Faults->System Faults.
Mode 1 Plugging Current Limit Not Used
Mode 1 Acceleration Rate Not Used
Mode 2 Plugging Current Limit 80
Mode 2 Acceleration Rate 1.0
Mode 2 Maximum Speed 100
6-3.7. Maintenance (Serial Number 373234 To
376836)
There are no user-serviceable parts inside the control-
lers. No attempt should be made to open the control-
ler. Opening the controller may damage it and will void
the warranty.
The transistor controller is programmed at the factory
specifically for the truck model on which it is equipped.
It is important to replace the controller with the correct
preprogrammed unit to assure proper performance
settings intended for that particular truck. See Figure
7-23 for the preprogrammed controller number.
It is recommended that the controller exterior be
cleaned periodically, and if a handheld programmer is
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.
6-3.8. Cleaning (Serial Number 373234 To 376836)
1. Remove power by disconnecting the battery.
2. Discharge the capacitors in the controller by con-
necting a load (such as a contactor coil or a horn)
across the controller's B+ and B- terminals.
3. Remove any dirt or corrosion from the bus bar
area. The controller should be wiped clean with a
moist rag. Allow it to dry before reconnecting the
battery.
4. Make sure the connections to the bus bars are
tight. Use two well insulated wrenches for this
task in order to avoid stressing the bus bars.
6-3.9. Diagnostic History (Serial Number 373234
To 376836)
The handheld programmer can be used to access the
controller's diagnostic history file. When the program-
mer is connected to the unit, the error log file is auto-
matically uploaded into the handheld programmer.
6-16
To see the present status of the unit, use the Menu
Navigation Key to select:
To access this log, use the Menu Navigation Key to
select:
Faults->Fault History.
The faults are shown as a code and descriptive text. If
there are multiple faults, you have to scroll through the
list using the Up and Down Buttons on the Menu Navi-
gation Key.
The faults may be intermittent faults, faults caused by
loose wires, or faults caused by operator errors. Faults
such as contactor faults may be the result of loose
wires; contactor wiring should be carefully checked
out. Faults such as HPD or overtemperature may be
caused by operator habits or by overloading.
After a problem has been diagnosed and corrected,
clearing the diagnostic history file is advisable. This
allows the controller to accumulate a new file of faults.
By checking the new diagnostic history file at a later
date, you can readily determine whether the problem
was indeed completely fixed.
To clear the diagnostic history file, select:
Faults->Clear Fault History.
You will be asked to confirm your actions. Use the
increment arrow (+) for yes and decrement arrow (-) to
cancel and not clear the Fault History.
6-3.10.Test the Fault Detection Circuitry (Serial
Number 373234 To 376836)
1. Put the vehicle up on blocks to get the drive wheel
off the ground.
2. Disconnect the battery and make sure the key-
switch is off.
3. Using an inline fuse holder fitted with a 10 amp
fuse and alligator clips, connect the controller's M-
and B- terminals.
4. Turn the keyswitch on, release the brake and
apply the throttle. The motor should not operate,
and the direction contactors should not pull in.
5. Leave the keyswitch on and remove the inline
fuse wire. The vehicle status should continue to
remain off.
6. Cycle the keyswitch off and on, release the brake,
and apply the throttle. The vehicle should now
operate normally.
PTW1104
 SECTION 7
ILLUSTRATED PARTS BREAKDOWN

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

PTW1104 7-1
 R5098

Figure 7-1 Control Head Assembly, Resistor

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

PTW1104 7-3
 R5099

Figure 7-2 Control Head Assembly - Transistor

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

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

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

PTW1104 7-5
 R5846

Figure 7-3 Steering Arm

INDEX PART NO. INDEX PART NO.

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

7-6 PTW1104
 INDEX PART NO.
NO. NO. PART NAME REQD.
1 061716 RING, SNAP, 5/8 2
2 402452 PIN 1
3 402459 CAP 1
4 — PIVOT CAP (FIGURE 7-3) 1
5 800288 BUSHING, PIVOT 2
6 051146 BEARING, THRUST 1
7 505680-01 PIVOT TUBE 1
8 069710 SCREW, FLAT HEAD 4
9 — TRANSMISSION ASSY REF
(FIGURE 7-6)

Figure 7-4 Pivot Tube Assembly

PTW1104 7-7
 R5144

Figure 7-5 Brake and Linkage

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

PTW1104 7-9
 R5311

Figure 7-6 Transmission Assembly

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

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

R5312

Figure 7-7 Drive Motor Assembly

INDEX PART NO. INDEX PART NO.

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

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

R6109

Figure 7-8 Drive Motor Assembly

INDEX PART NO. INDEX PART NO.

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

PTW1104 7-13
 R5313

Figure 7-9 Base and Frame

INDEX PART NO. INDEX PART NO.

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

7-14 PTW1104
 NOTES

PTW1104 7-15
 R5314

Figure 7-10 Fork Section Assembly

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

PTW1104 7-17
 R5324

Figure 7-11 Hydraulic System Installation

INDEX PART NO. INDEX PART NO.

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

7-18 PTW1104
 R4356

Figure 7-12 Pump, Motor and Reservoir Assembly

INDEX PART NO. INDEX PART NO.

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

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

R5325

Figure 7-13 Hydraulic Cylinder Assembly

INDEX PART NO. INDEX PART NO.

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

7-20 PTW1104
 R5315

Figure 7-14 Storage and Batteries and Connector

INDEX PART NO. INDEX PART NO.

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

PTW1104 7-21
 1
3

R5695

Figure 7-15 Quick Disconnect Cable Installation

INDEX PART NO.

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

7-22 PTW1104
 R5320

Figure 7-16 Horn Installation

INDEX PART NO.

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

PTW1104 7-23
 R5316

Figure 7-17 Electrical Installation, Resistor

INDEX PART NO.

NO. NO. PART NAME REQD.
1 023224 HARNESS ASSEMBLY, PUMP 1
2 504364 NUT AND CLAMP ASSEMBLY 2
3 023228 CABLE ASSEMBLY, PIVOT TUBE 1
4 069478 SCREW, MACHINE, FLAT HEAD 2
5 056141 CLAMP, CABLE 2
6 077211 WASHER, LOCK 4
7 059429 NUT, HEX 4
8 505547 CABLE ASSEMBLY, DEADMAN 1
9 005405 RELIEF, STRAIN 1
10 020729 SWITCH, DEADMAN 1
11 505544 PANEL ASSEMBLY CONTACTOR 1
(SEE FIGURE 7-21)

7-24 PTW1104
 R5318

Figure 7-18 Electrical Installation, Transistor

INDEX PART NO.

NO. NO. PART NAME REQD.
1 023224 HARNESS ASSEMBLY, PUMP 1
2 504364 NUT AND CLAMP ASSEMBLY 2
3 023223 CABLE ASSEMBLY, PIVOT TUBE 1
4 069478 SCREW, MACHINE, FLAT HEAD 2
5 056141 CLAMP, CABLE 2
6 077211 WASHER, LOCK 4
7 059429 NUT, HEX 4
8 505547 CABLE ASSEMBLY, DEADMAN 1
9 005405 RELIEF, STRAIN 1
10 020729 SWITCH, DEADMAN 1
11 505544 PANEL ASSEMBLY CONTACTOR 1
(SEE FIGURE 7-21)
12 504116 SPIKE SUPPRESSOR ASSEMBLY 1
13 504097 SPIKE SUPPRESSOR ASSEMBLY 1

PTW1104 7-25
 R5516

Figure 7-19 PTW Battery Charger Installation

INDEX PART NO. INDEX PART NO.

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

7-26 PTW1104
 NOTES

PTW1104 7-27
 R5317

Figure 7-20 Contactor Panel Assembly, Resistor

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

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

R5319

Figure 7-21 Contactor Panel Assembly, Transistor

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

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

R4133

Figure 7-22 Contactor Panel Assembly, E Rated Transistor

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

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

R6130

Figure 7-23 Contactor Panel Assembly, E Rated Transistor

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

PTW1104 7-35
 R5328
R5332

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

INDEX PART NO. INDEX PART NO.

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

7-36 PTW1104
 R5329

Figure 7-26 Cold Conditioning Package Installation - Option

INDEX PART NO. INDEX PART NO.

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

* FOR INTERMITTENT OPERATION BELOW 32 ° F.

** FOR CONTINUOUS OPERATION BELOW 32° F.

PTW1104 7-37
 R5330

Figure 7-27 Hourmeter Installation - Option

INDEX PART NO. INDEX PART NO.

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

7-38 PTW1104
 R5331

Figure 7-28 Load Backrest - Option

INDEX PART NO.

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

PTW1104 7-39
 R5641

Figure 7-29 Caster

INDEX PART NO. INDEX PART NO.

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

7-40 PTW1104
Big Joe Manufacturing Company