RI Manual 901338 Model PTW-40 S/N Prior to 344638 This manual is affected by the following BULLETINS: These are found in the bulletin folder of the navigation screen. Bulletin Rev 159 187 200 207 220 A 232 238 245 246 A 262 271 272 275 Title PTR Pallet Truck Transistor Speed Controller Electrical Control Cable Installation Transistor Control Head Transistor Control Head Trans Controller/Contactor Pan (Type E) Pump Motor-Reservoir Assembly 016594 Battery Safety and Maintenance Pushbutton Trucks Smart Charger 004977-01 Pivot Weldment Battery Quick Disconnect Cable Kits Wheel Housing Kit 901622Operation + Maintenance ~- Repair parts list PALLET TRUCK, POWERED ELECTRIC, 24 VOLT, 4000 LB CAPACITY INDUSTRIAL WALKIE TRUCK PRIOR TO SERIAL NUMBER 344639 ‘SEE SUPPLEMENT 159 FOR PTR TRUCKS. 4 BIG); =JQE. Manufacturing Company - Lincolnwood, IL 60646 = Ob-Mld 00'S2$ 301d IWAN Rev. D 10/90 Manual No. 901338A WARNING DO NOT OPERATE THIS TRUCK UNLESS YOU HAVE BEEN TRAINED AND AUTHORIZED TO DO SO, AND HAVE READ ALL WARNINGS AND INSTRUCTIONS IN OPERATOR'S MANUAL AND ON THIS TRUCK’ DO NOT OPERATE THIS TRUCK UNTIC YOU HAVE CHECKED ITS CONDITION. GiVE SPECIAL ATTENTION TO TIRES, HORN, BATTERY, CONTROLLER, LIFT SYSTEM, BRAKES, STEERING MECHANISM, GUARDS AND SAFETY DEVICES. OPERATE TRUCK ONLY FROM DESIGNATED OPERATING POSITION. WEAR FOOT PROTECTION. OO NOT CARRY PASSENGERS, OBSERVE APPLICABLE TRAFFIC REGULATIONS. YIELD RIGHT OF WAY TO PEDESTRIANS. SLOW DOWN AND SOUND HORN AT CROSS AISLES AND WHEREVER VISION IS OBSTRUCTED. START, STOP, TRAVEL, STEER AND BRAKE SMOOTHLY. SLOW DOWN FOR TURNS AND ON UNEVEN OR SLIPPERY SURFACES THAT COULO CAUSE TRUCK TO SLIDE OR OVERTURN. USE SPECIAL CARE WHEN TRAVELING WITHOUT LOAD AS THE RISK OF OVERTURN MAY BE GREATER. ALWAYS LOOK IN DIRECTION OF TRAVEL. KEEP & CLEAR VIEW, AND WHEN LOAD INTERFERES WITH VISIBILITY, TRAVEL WITH LOAO OR LIFTING. MECHANISM TRAILING, USE SPECIAL CARE WHEN OPERATING ON RAMPS TRAVEL SLOWLY, AND DO NOT ANGLE OR TURN, TRAVEL WITH LIFTING MECHANISM DOWNHILL, 100 NOT OVERLOAD TRUCK. CHECK CAPACITY PLATE FOR LOAD WEIGHT AND LOAD CENTER INFORMATION. 100 NOT HANDLE LOADS WHICH ARE HIGHER THAN THE LOAD BACKREST OR LOAD BACKREST EXTENSION UNLESS LOAD IS SECURED 50 THAT NO PART OF IT COULD FALL BACKWARD. BEFORE LIFTING, BE SURE LOAD IS CENTERED, FORKS ARE. COMPLETELY UNDER LOAD, AND LOADS AS FAR BACK AS POSSIBLE AGANIST LOAD BACKREST. WHEN LEAVING TRUCK, NEUTRALIZE TRAVEL CONTROL, FULLY LOWER LIFTING MECHANISM ANO SET BRAKE, WHEN LEAVING. TRUCK UNATTENDED, ALSO SHUT OFF POWER. PIW 056613TABLE OF CONTENTS Section Page OPERATOR INSTRUCTIONS, sonsecnane Hi PREPARATION FOR USE ... 1 DESCRIPTION..... Tel Introduction nn 1-2 General Description .. 1-3 Name Plate 1-4 Safety Features 1-5 Option 1-6 Decals 1-7 Touch-Up Paint OPERATION 2-1 General 2-2 Operating Precautions 2-3 General Control Operation .. 2-4 Driving and Stopping Procedures 2.5 Belly-Button Switch .. 2-6 Steering Arm Retum Spring 2-7 Lift and Lower Controls, 2-8 Loading and Unloading 29 Parking : IM MAINTENANCE 1 General 3-2 Operator Daily Checks 3-3 Monthly and Quarterly Checks 3-4 Battery Care on : 3-5 Lubrication PTW-40 Section Page IV ADJUSTMENT AND REPAIR 4-1 Steering Arm and Control Head 4.2 Brake Service .. 4:3 Transmission, Drive Motor an« Pivot Tube Assembly 4-4 Base, Frame and Forks 4-5 Electrical 4-6 Hydraulics ve 4210 V OPTIONS. 5-1 Keyswitch 54 5-2 Hour Meter 51 5-3 Battery Discharge Indicator 5:4 Cold Condioning Package 5-5 Stabilizer 5-6 Backrest 5-7 Casters. VI TROUBLESHOOTING 61 6-1 Troubleshooting Chant 61 6-2 Contactor and Switch Troubleshooting 6-3 Charger TroubleshootingLIST OF ILLUSTRATIONS Page PTW.40 Litt Truck 1 Steering Arm Controls, prior to SIN 332483. 2-1 Steering Arm Controls, SIN 332483 and Higher .. ey Brake = ea Lubrication Diagram 34 Belly-Button Switch Adjustment at Control Head! Assembly, prior to S/N 332483 43 4-3. Control Head Assembly, S/N 332483 and Higher sana 48 4-4 Steering Arm 47 45. Electrical Contral Cable Replacement 49 4.6 Brake Adjustment. prior to S/N 333080 oon. 4-10 4-7 Brake Adjustment, S/N 333080 and Higher .. 4-10 4-8 Brake and Linkage. prior to S/N 333080 ..... 4-11 4-9 Brake and Linkage, S/N 333080 and Higher . 4-13 4:10 Pivot Arm ASSEMBLY. vonnsnen aig 41 Transmission soe : 416 4-12 Drive Motor. prior to SIN 333706 418 4-13 Drive Motor, S/N 333706 and Higher soso 419 4-14 Base, Frame and Fork Section wesnsmnnnne 420 4-15 Fork Section Details, for Trucks prior 10 SIN 317949 ... 421 4-16 Fork Section Details. for Trucks S/N 317949 and Higher sense ADD 4-17 Buckrest Dimension Set-Up sven 425 4-18 Electrical Components 4.19 Contactor Panel isle Pole Contact 4.27 4-29 Unit Figure Page 4.21 Double Pole Contactor Unit saeuee 431 4.22 Battery Charger Mounting, 432 4.23. Battery Charger «.... on Wiring Diagram PTW-80 Truck... 434 Electrical Schematic sess 43S Hydraulic System se 4-36 Pump-Motor-Reservoir Assembly 437 Pump Motor Assembly for Trucks prior to SIN 318250 438 4.29 Pump Motor Assembly, on Trucks S/N 318250 thru 325168, and 332121 thru 335304 .. 4.30. Pump Motor Assembly, on Trucks ‘S/N 325169 thru 332120, and, 335305 and Higher 4-31 Lift Cylinder, P/N 504712 4.32. Lift Cylinder, P/N 047570 5-1 Keyswitch 5-2. Hour Meter Installation 5-3. Battery Discharge Indicator Installation 5-4 Cold Conditioning Package, prior to 4.39 SIN 332483 ne . 55 Cold Conditioning Puckage, S/N 332483 ‘and Higher = 5-6 Stabilizer 5-7 Backrest SB Casters 6-1 Contactor Testing. 6-2 Switch Testing 63. Diode Test LIST OF TABLES Table Page Table BL Daily Checks ' 1 Recommended Lubricants 3.2 Monthly ane! Quarterly Inspection ant Lubrication Chart Service Chart Adjustable Pull Rod Kit Numbers 3:3. Charge Time for Battery Charging .. Additional Part Numbers for Figure 4-16 ..OPERATOR INSTRUCTIONS WARNING Do not operate this truck unless you have been trained and authorized to do so and have read all warnings and instruc- tions in operator's manual, and decals affixed to this truck, see Figure !-1. Do not operate this truck until you have checked its condi tion. Give special attention to Tires, Hom, Lights, Battery, Controller, Lift System, Brakes, Steering Mechanism, Guards and Safety Devices. Operate truck only from designated operating position. Wear foot protection, Do not carry passengers. Observe applicable traffic regulations, Yield right of way to pedestrians. Slow down and sound hom at cross aisles and wherever vision is obstructed. Stan, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could ccause truck 10 slide or overtum. Use special care when traveling without load as the risk of overturn may be greater. Always look in direction of travel. Keep a clear view, and when load imerferes with visibility, travel with load or li ing mechanism trailing, Use special care when operating on ramps-travel slowly. and do not angle of turn. Travel with lifting mechanism or load downhill PTW-40 Do not overload truck. The center of gravity of a capacity Toad can not exceed the load center specified on the name plate for your truck, as configured at time of delivery from factory. See diagram below for load center location. Addi- tional lifting equipment such as removable payload plat- forms and special attachments may alter the load center, and consequently lower the rated lifting capacity of the truck, Before lifting, be sure load is centered, forks are com- pletely under load, and load is as far back as possible against load backrest. Do not handle loads which are higher than the load back- rest or load backrest extension unless oad is secured so that no part of it could fall backward. When leaving truck, neutralize travel control. Fully lower lifting mechansim and set brake. When leaving truck unat- tended, also shut off power. iliPREPARATION FOR USE Upon receipt, visually inspect the truck. If any damage is found, report it to the carrier and to your Big Joe dealer immediately Remove cardboard banded to forks. Check lift truck for scratches and dents. Inspect for oil leaks and loose wiring connections. Make certain that all accessories that were ordered are supplied. Before the lift truck is moved, the battery must be checked, recharged if necessary, and connected. Refer to ‘Battery Care” in Section Ill for battery checking instruc- tions. If you did not order an optional charger cord (Figure 4-22), then purchase an extension cord, 16 ‘gauge, 3 wire, UL approved of the type normally used for shop tools, heavier appliances, etc. Refer to Section II for operating instructions to test the brakes and lift control If you do not obtain the proper results, or if improper ‘operation occurs, refer to TROUBLESHOOTING, SEC- TION VI and ADJUSTMENT AND REPAIR, SECTION IV. The adjustment and repair procedures are supple ‘mented with illustrations and parts lists. All pans identification illustrations have been integrated ‘with the text rather than separated into a special section. PTW-40SECTION! DESCRIPTION 441. INTRODUCTION. This publication describes the PTW-40 lift truck manufac tured by Big Joe Manufacturing Company, Lincolnwood, IMlinois 60646. Included are operating instructions, planned maintenance instructions, lubrication procedures, corrective maintenance procedures and a complete parts list with parts location illustrations. By following the recommendations contained in this ‘manual, you will receive many years of dependable serv- ice from your Big Joe lift truck. 1-2. GENERAL DESCRIPTION. ‘The self-propelled PTW-40 lift ruck Figure 1-1, lifts and transports payloads up to 4000 pounds on rigid forks. The forward and reverse motion is controlled by a rocker type switch in the control head, on trucks prior 0 serial number 332483. On tucks serial number 332483 and higher, direction of travel is controlled by rotation of the speed control at the hand grips. Stopping and turning is controlled by the steering arm, Lift and Lower is control- led by pushbuttons located on the control head. ‘The battery-powered lift ruck is quiet and without exhaust fumes. ‘The reversible DC motor propels the lift truck in forward or reverse direction throughout the available speed range. The PTW-a0 lift truck can be driven with forks raised or lowered 056613 ‘OPER: INSTR. PTW-40, DECAL BIG JOE DECAL, (086475 Prior To SiN 330008 (056631 For S/N 330008 and Higher NAME PLATE 4-3. NAME PLATE. (Figure 1-1) ‘The name plate provides specific information pertaining to ‘your PTW-40, See Figure 1-1 for location of name plate, and serial number location, if the name plate is missing or illegible. 1-4, SAFETY FEATURES. ‘The PTW-40 lift truck is designed and engineered 10 provide maximum safety for operator and payload. Some of the safety features incorporated into the design are: Deadman brake to apply mechanical brake and cut off drive power when the steering arm is released. Belly-button switch to reverse truck should the operator accidentally pin himself against a wall or obstruction when backing up. Al control functions automatically return to "OFF" when released. Extemally accessible quick-disconnect battery plug within operator's reach. ‘Separately fused control circuits and power circuits. Readily accessible HORN button. Load backrest to help stabilize the load. ‘Neoprene hand grips on trucks prior to S/N 332483, ‘and knurled hand grips on trucks S/N 332483 and higher provide a firm hand hold for operator. CAUTION DECAL SERIAL NUMBER LOCATION Figure 1-1. PTW-40 Lift Truck PTW-40 11Flow control valve regulates maximum lowering speed ‘within prescribed limits ‘Automatic relief valve maintains hydraulic pressure within prescribed limits. High visibility color scheme of truck provides visual alert of trucks presence. 1-5. OPTIONS. Big Joe offers many options and accessories for the PTW- 440 lift truck such as: Keyswitch Cold Conditioning Battery Capacity Indicator Hour Meter For Motors Stabilizer Bars Charger Cord 240 V, 50 He, Single Phase Charger Load Backrest Extension Poly Drive Wheel Casters 12 1-6. DECALS. It is important that all decals be affixed and legible. Re- place those that have come off or become unreadable. Or- der individually (see Figure 1-1) or order Decal Kit 901039. 4-7. TOUCH-UP PAINT. Maintain the appearance of your PTW-40 lift truck. Serial Number prior to 330008: Brown Paint - 055811 ‘Orange Paint - 055810 Serial Number 330008 and highé Yellow Paint - 901201 Black Paint - 901202 PTW-40SECTION II OPERATION 24. ‘SEE SUPPLEMENT 159 FOR PTR TRUCKS ‘SEE SUPPLEMENT 220 FOR TRANSISTOR ‘SPEED CONTROL TRUCKS This section gives detailed operating instructions for the PTW-40 lift truck. The instructions are divided into the various phases of operations, such as operating lif, driv- ing, and stopping. Routine precautions 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 precau- tions when operating the PTW lift ruck. GENERAL. 1. Do not operate this truck unless you have been trained and authorized to do so and have read all warnings and instructions in operator's manual and on this truck, Do not operate this truck until you have checked its condition. Give special attention to Tires, Hom. Lights, Battery, Controller, Lift System, Brakes, Steering Mechanism, Guards and Safety Devices. 3. Operate track only from designated operating position. ‘Wear foot protection. Do not carry passengers. Observe applicable traffic regulations. Yield right of way to pedestrians, Slow down and sound hom at cross aisles and wherever vision is obstructed. FORWARD Speco. CONTROL BELLY BUTTON 4. Start, stop, travel, steer and brake smoothly. Slow down for tums and on uneven or slippery surfaces that could cause truck to slide or overtum. Use special care When traveling without load as the risk of overtum may be greater. 5. Always look in direction of travel. Keep a clear view, and when load interferes with visibility, travel with Joad or lifting mechanism trailing. 6. Use special care when operating on ramps-travel slowly, and do not angle or tum. Travel with lifting ‘mechanism or load downhill 7. Do not overload truck. Check name plate, Figure 1-1, for maximum capacity and load center information See Warning, Page iii for information on safe and un- safe load center conditions. 8. Do not handle loads which are higher than the load backrest or load backrest extension unless load is secured so that no part of it could fall backward. 9. When leaving truck, neutralize travel control. Fully lower lifting mechanism and set brake. When leaving truck unattended, also shut off power. 2-3. GENERAL CONTROL OPERATION. 2-3-1. Operation Prior To S/N 332483. The speed control (see Figure 2-1) located inside the bel- Iybutton switch-guard provides fingertip control for driv- ing the truck. As the upper portion of the speed control is pressed, it closes contacts for first speed in the forward direction. Pressing the speed control farther closes a con- tact for second speed and farther, third speed. Third speed THORN PUSHBUTTON LIFT PUSHBUTTON LOWER PUSHBUTTON Figure 2-1. Steering Arm Controls, prior to S/N 332483. PTW-40‘may be cut out by a rocker switch located on the control crown, The lower portion of the speed contral governs the three reverse speeds in the same manner. Switch boxes, located on both sides of the steering arm control, contain parallel lift-lower controls to allow operation from either side of the control head. Parallel horn buttons are also lo- cated on each side of the control head in the switch boxes. Lowering the steering arm below the horizontal or raising to the vertical applies the brake. (See Figure 2-3.) All trac- tion control power is shut off when the brake is engaged. When the steering arm is in the upright position, the brake acts as a parking brake. Deadman braking occurs when the handle is released and spring action raises it to the upright position. 2-3-2. Operation for SIN 332483 and Higher. AAs the upper portion of the speed control (see Figure 2-2) is pressed or the grips rotated, contacts are closed for first revERse HORN PUSHBUTTON, BELLY-BUTTON. swiTcH GUARO FORWARD, ‘Sreeo Lowen CONTROL speed in the reverse direction. Pressing the speed control farther closes a contact for second speed and farther, third speed. On some models, third speed may be cut out by a rocker switch located on the control crown. The lower por- tion of the speed control governs the three forward speeds in the same manner. Push bottom switches located on the steering arm control, provide lift-lower controls and horn. Lowering the steering arm to the horizontal or raising 10 the vertical applies the brake. (See Figure 2-3.) All trac- tion control power is shut off when the brake is engaged. ‘When the steering arm is in the upright position, the brake acts as a parking brake. Deadman braking occurs when the handle is released and spring action raises it to the vertical Position, High speeD (oN some moDeLs) s << so 8 6x STEERING aRM IF ROTATING GRIPS ‘ARE PREFERRED, Figure 2-2. Steering Arm Controls S/N 332483 and higher. PTW-40‘CONTROLS ARE ENERGIZED. MECHANICAL BRAKE STARTS TO ENGAGE, CONTROLS ARE ENERGIZED. MECHANICAL BRAKE CconTRoLs ARE DE-ENERGIZeD. CONTROLS ARE MECHANICAL BRAKE IS DISENGAGED. ‘CONTROLS ARE DeENEnGIzeD. MECHANICAL BRAKE 18 ENGAGED. sive view MECHANICAL BRAKE 18 ENGAGED, Figure 2-3. Brake 2-4. DRIVING AND STOPPING PROCEDURES. AF the PTW-40 truck is equipped with a keyswitch, turn it to the on position 1. Grasp the grips of the steering arm so that the speed control can be comfortably operated by either thumb. Lower the steering arm 10 a comfortable pos above horizontal to disengage the brake and to ener- ‘ize the electrical circuits. 3. To move forward, slowly press the forward speed con- trol. Press the forward speed control farther to increase speed. NOTE: On trucks serial number 332483 and higher, the direction of travel indications are op- posite those of trucks prior to serial number 332482. PTW-40 4, To stop, release the speed control and lower the steer- ing arm to the horizontal position. In this position, the brake pads apply light pressure to the brake disc Lowering the steering arm below horizontal increases the braking force. ‘The brake may also be applied by raising the steering, arm to the upright position. 5. To travel in reverse, lower steering arm to a comfort- able position and slowly press the reverse speed con- trol. NOTE: Acceleration in reverse is the same as in the forward direction. 232:5. BELLY-BUTTON SWITCH. (Figure 2-1 or 2-2) ‘The belly-button switch minimizes the possibility of the driver being pinned by the steering arm while driving the life truck. If the guard presses against the driver while the lift truck is being driven with control head leading, the ‘guard actuates a switch which changes the direction of the lift ruck away from the operator, 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 retum fully, the steering arm return spring requires ad- Justment, Return truck to maintenance for adjustment. 2-7. LIFT AND LOWER CONTROLS. Dual Lift/Lower Control butions are located on each side of the steering control head (Figure 2-1), on trucks prior to SN 332483, The Lifi/Lower Control buttons on trucks SN 332483 and higher are located inside the belly button switch guard (Figure 2-2), To lift forks, push in LIFT button and hold until forks reach desired height. To lower forks, push in LOWER but- ton and hold until forks descend to desired height 24 2-8. LOADING AND UNLOADING. 1. Move truck to location where load isto 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 Tift Toad. 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 to remove {forks from pallet. 2.9. PARKING. When finished with moving loads, drive truck to its main- fenance or storage area. Disconnect batteries from TRUCK receptacle and connect to CHARGER receptacle. Charge batteries as necessary. Refer to battery care instruc- tions, paragraph 3-4. PTW-40SECTION II MAINTENANCE 341, GENERAL. CAUTION: If the truck is found to be in need of repai Maintenance includes both the operator daily check proce- dures and scheduled maintenance which must be per- formed by a qualified service technician. Any needed serv- ice found during the operator daly check or the monthly and quarterly scheduled maintenance procedures must be performed by a qualified maintenance technician 3:2. OPERATOR DAILY CHECKS. ‘Table 3-1 is a check list identifying both visual and opera- tional checks which must be performed by the operator on daily basis to insure the safety of the equipment. Table 3-1. Daily Checks or unsafe, or contributes to an unsafe condi tion, report it immediately to the designated authority. Do not operate the truck until it has been restored to safe operating condi- tion, If during operation, the truck becomes un- safe, report it immediately to the designated authority. Do not operate truck until it has ‘been restored to safe operating condition. Do not make any unauthorized repairs or ad- Justments, VISUAL CHECKS VISUAL CHECKS 1TEM [PROCEDURE TEM PROCEDURE DAMAGE [Check for bent, denied or HORN (Check for sounds. broken pars. STEERING Check for binding, or LEAKS Check drive unit and hy- excessive play. rae system. TRAVEL Check all speed ranges, for TIRES AND WHEELS |Check drive whel and load ward and reverse. No unusual wheels for damage, binding, noise should be present. ee HYDRAULIC (Check lift and lower for bind- FORKS Check for bends and mis- CONTROLS ing or unusualy noses, etc. alignment BRAKES Check that brake stops truck CABLES AND HOSES| Check that they are in place within a safe distance and and not damaged works smoothly. Check dead- man brake by releasing BATTERY Check water level, and vent handle. caps for damage or plugging. HOUR METER —_|f equipped, check for proper BATTERY Check for cracks, bums and operation, CONNECTOR for tight connections with truck receptables, PARKING BRAKE _ | Holds tuck in place GuaRDs Check toad backrest covers BATTERY CHARGE |Check that battery capacity and guards for damage. meter (i equipped) ison “full” or specific gravity of SAFETY DEVICES | check that warning labels, batteries indicates full charge lata plates ete. ae in the same condition as original ly equipped. PTW-40 at‘Table 3-2. Monthly and Quarterly Inspection and Service Chart INTERVAL INSPECTION OR SERVICE Monthly Check condition of drive motor Commutaior. brushes and springs Monthly Check condition of pump motor commutator, brushes and springs Monthly Check mechanical brake for proper operation Monthly Check load wheels for wear Monthly Check dive wheel for wear Monthly Inspect wiring for loose connections and damaged insulation Monthly Inspect contactor tps for excessive pitting and wear Monthly Check deadman brake switch for proper operation Quarry Replace hydraulic strainer assembly Quarterly Check if eylindr wiper ring and packing Quarerly Check for excessive jerking of steering arm when stopping or starting 9-3. MONTHLY AND QUARTERLY CHECKS. ‘Table 3-2 is a monthly and quarterly inspection and serv- ice chart based on normal usage of equipment eight hours per day, five days per week. Ifthe lift truck, is used in ex- ‘cess of forty hours per week, the frequency of inspection and service should be increased accordingly. These proce- dures must be performed by a qualified service technician cof your Big Joe service representative, 34. BATTERY CARE. A. General. “The life of the battery can be extended by giving it proper care. Perform a daily check of the battery whether or not the equipment isin daily se. DO NOT overcharge the bat tery or batery life will be shortened. DO NOT allow bat- tery t0 become completely discharged (specific gravity 1.150 or less). This will also greatly shorten battery life. B. Battery Removal. CAUTION: These batteries are heavy. Use handles on battery when lifting. Removal of batteries requites that they be lifted up out of their compartments. A hoist and sling will ease removal of batteries. a2 When reinstalling the battery be sure handles are securely fastened to battery, battery cable connectors are securely attached to the battery terminals and cables are routed and secured to the battery as shown in Figure 4-18. C. Testing and Charging Batteries. Use the following procedure. |. Obtain a battery hydrometer. NOTE: These can be obtained from a local hardware store or automotive shop. 2. Use the hydrometer to check specific gravity of each cell, NOTE: Battery specific gravity readings should agree within 40.025 from cell to cell. If variation is greater, the battery may have to bbe repaired or replaced. CAUTION: Be sure that no cell plates are exposed (not covered by fluid) before charging. Add dis- tilled water sufficient to just cover top of cell plates. CAUTION: Use Distilled water. Impurities in tap water will damage battery plates. PTW-403. Charge battery in accordance with table 3-3. NOTE: ‘A fully charged battery has a specific gravity of 1.260 to 1.275. 4, After charging, check water level in each cell again, Water level must cover plates but not be higher than the base of the battery cel filler neck ‘Table 3-3. Charge Time for Battery Charging 3-5. LUBRICATION. Refer to table 3-4, for the recommended types of grease and oil. Table 3-5 in conjunction with Figure 3-1 identifies the items requiring lubrication, ‘Table 3-4, Recommended Lubricants (See Table 3-5 for Application) No.! “Transmission oil- EP SAE 80W-90 Amount required - 1 qt. Big Joe No. 055780 SPECIFIC CHARGE TIME No.2 Grease - Lithium base, general purpose. GRAVITY 15 AMP CHARGER 200 AH BATTERIES No.3 Hydraulic oil - Heavy duty with a vis-| 1.250) 2 cosity of 150 SUS (in temperatures below 1.240 4 200" F use 100 SUS) foam suppressing| 1.220 5 agent and rust and oxidation inhibitors. 4.200 8 Quy. | gal. 1.180 10 Big oe No, 900855 1.160 2 1.140 4 No.4 Engine lubricating oil - No. 20 PTW-40Fig. 3-1 Type ‘Application Index Method Of | (Table) of No. Location Application G4) Lubricant 1 | Channet Gun No.2 | Pressure lubricate Roller Bearings 2 | Steering Arm Elbow Can No.4 | 10r2 drops each time serviced 3 | Pivot Tube Bushings Gun No.2 | Pressure lubricate 4 | Transmission Reservoir Can No.1 | Fillo plug level 5 | Lift Carriage Channels Brush No.2 | Full length of channel (inside) 6 | Hydraulic System Can No.3 | Lower carriage, fill reservoir to plug level 7 | Pivot Bearings Can No.4 | 1or2 drops each time serviced. (See Figures 4-15 or 4-16, Item 6, 13, 16, 23 &27) SEE TABLE 3.5, Figure 3-1. Lubrication Diagram 34 PTW-40SECTION IV. ADJUSTMENT AND REPAIR 4-1, STEERING ARM AND CONTROL HEAD. ‘SEE SUPPLEMENTS 187, 207, AND 220 FOR TRANSISTOR CONTROL TRUCKS ‘A. Belly-Button Switch Adjustment. (Figure 4-1.) If the actuator gap of the belly-button switch needs adjustment, proceed as follows: 1. Disconnect the battery, 2. Drive the roll pins that secure the belly-button casting out. (Figure 4-1.) Drive from the left to the right NOTE: 3. Bend actuator lever of belly-button switch to adjust gap between roller and belly-button casting as re- Quited. (See Figure 4-1.) CAUTION: Too small a gap between belly-button While removing the belly-button casting, the two return springs will drop free. Catch the springs while pulling the casting away to prevent their loss, switch actuator roller and the belly-button casting may cause the belly-button switch to be actuated constantly. BELLY BUTTON CASTING cast 1 BELLY BUTTON SWITCH see Text Gap. ROLLER BELLY, BUTTON ‘SPRING 4, Reinstall belly-button casting, making certain all parts are back in place. 5. Check operation of the belly-button safety switch by pressing the belly-button casting while listening for the "click" that indicates thatthe switch has actuated. NOTE: The click should be heard when the belly-button casting has moved about 50 percent of its normal travel distance. If the click is heard atthe beginning of travel, the switch may actuate at inappropriate times. If the click is heard near the end of travel, it could be unreli- able and may not switch in some instances. Repeat steps 2 through 5 until pressing the belly-button ‘casting actuates the switch properly. |. Reconnect the battery. WARNING: Testing of belly-button safety switch in ‘operation should be limited to areas clear of obstacles against which an operator could be pinned. Use low speed. BELLY BUTTON ‘SUPPORT NG END Rene Ss NEEDED Figure 4-1, Belly-Button Switch Adjustment PTW-40 44B. Control Head Switch Replacement, Prior To SIN 332483. 1. Disconnect the battery. NOTE: Access to belly-button switch is provided by removal of belly-buton casting: access 10 the hom, lift and lower pushbuttons is provided by removal of right and left side switch boxes. Access to the speed control switch is provided by removal of the handle wweldment. 2. Remove belly-button casting (39, Figure 4-2) by per- forming steps | and 2 in paragraph 4-1A, if necessary to gain access to defective belly-button switch, 3. a, Remove socket head screws (17, Figure 4-4) to detach control head and gain access to speed con- trol hamess (14). b. Disconnect speed control hamess and remove screws (30, Figure 4-2) holding connector mount- ing plate (35). Move plate with connector (34) to desired location. . Disconnect pushbutton switch (36) and remove from switch box (25 andjor 27). See Figure 4-2. 4. Remove hex head screws (47) to detach handle weld ‘ment (54) and flat head serews (20) to gain access to speed control switch (12). See Figure 4-2 ‘5. When replacing switch covers (3, Figure 4-2), trim cor- ner as shown in Illustration A. This allows covers 10 clear the ends of the spring when the lever is in neutral and when it is rotated. DO NOT CUT SPRING. Spring. and switch cam must be lubricated before reassembly. (oor ese) 42 CAUTION: USE GREASE SPARINGLY. a. Coat retum spring (14, Figure 4-2) per Mustra- tion B. Separate coils slightly to assure penetration of grease. MoW'enense b. Lightly coat the switch cam per Ilustration C only con the surfaces where switch rollers come in con- tact with cam, CAUTION: Do not allow any grease to drop on the printed circuit board. USE A MOLY GREASE (MS.). 6. Replace the speed contro! switch (12), belly-button switch (43), horn switch, and lift-lower switches (36) a required. See Figure 4-2. NOTE: If the belly-button switch is replaced, adjust it in accordance with paragraph 4-14 before using truck. 7. After replacing defective switch(es), reinstall switch bbox and/or belly-button casting, as required, making certain that all parts are put back in place. 8, Reconnect electrical connectors and connect battery. © cemteee PTw-40‘SEE SUPPLEMENT 246 FOR PUSHBUTTON CHANGE noe NO, 1 2 3 4 5 6 7 a 9 10 " 2 3 4 5 6 ” 8 19 2 2 25 6 Part ‘NO. ‘S04719 900735, ‘00214 055516 074708 (075074 osrata 055367 052813 o7a710 o72a15, os2018 e203 055517 075073 052819 067413 052812 o7eats os96a2 ogsa6t o7erit 7502 056598 00221 065456 PTW-40 SPEED CONTROL SWITCH 900735 Figure 4-2. Control Head Assembly, Prior to SN 332483, PART NAME REQD. No. Control Head Assombly, Sid PTW 40 1 ‘Speed Control Switch ‘Speed Control Laver Switch Cover Spacer Ball Retainer Serow, Pan Hd, 5-40 x 1/4 Ball Bearing, 16 ia, Spring Retainer Prvot Sha Screw, Pan Hd, Thread Cutting, 440x538 ‘Switch Plato P.C. Bd and Switch Assembly Switch Cam aturn Speng ‘Spring Retainer Spacing ‘Serow Pan Ho, 5:40 x 1/2 ‘Switch Enclosure, Speed Control ‘Switch Box ‘Screw, Fat Hd, 5-40 x V2 "Tha Cutting Nut Hox, 5-40 Scrow, Fiat Hd, 5-40 x 2 Gio Forward-Reverse Decal Not Used Box Switch, 3-Holes, RH Screw, Sockot Hd, Cap, 10-24 x 5/8 INDEX NO. 27 28 2 20 Et 2 2 3 35 6 37 38 a 0 a 2 a a 6 6 a7 8 ry 50 3 3 5 54 55, NS PART NO. 300220 503797 077207 grata 77203 59410 068177 023138 (052820 20771 005647 300216 00215 ost018 059633 504538-01, ‘o2066e 70486 075510 77208 oss4o1 ‘orsace 056612-01 056812.02 1020688 o72at4 05651203, 503912 056580 055765 5 PART NAME Box Switch, $-Holes, LH Handlo and Tube Weldmont ‘Washer, Lock, Spit, No. 10 Screw, Pan He, 10-24 x 318 ‘Washer, Lock, Spit No. 5 Nut, Hex 5-40 Scrow, Machine, Pan Hd, 5-40 x 9/8 Speed Control Hamess-STD Connector Mounting Plate Pushbutton Switch ‘Connector, Free Hanging Button Support Casting Belly-Button Casting Rol Pin, 14 x3-12 19 Locknut, Hex 256 Hamess Assembly ‘Microswitch, 250 Vots AC ‘Scrow, Fn Hd, 2-56 x 94 Bely-uton Spring Washer, Lock, Spl. 1/4 ‘Screw, Hex Hd, 14-20 x 31/2 Ineulator FRaise Pushbutton Lower Pushbution ‘Third Speed Switch ‘Seraw, Pan Hd, 4-40 x 172 Horn Button, Red HDL Weldment Decal. Srd Speed Lockie, 280 Adhesive 8 F-nnwanmasenmeuneanonann nanan éC. Control Head Switch Replacement, S/N 932483 and higher. 1, Disconnect the battery. NOTE: Access to belly-button switch (3, Figure 4-3) 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 4-1A, if necessary to gain access to a defective belly-button switch. NOTE: Switch operation may be checked with a Continuity light containing a battery, or with ‘an ohmmeter, 3. Replace a defective belly-button switch (3) as follows: 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). © Connect electrical wires 10 new belly-button switch (3) as noted during removal. Parts List For Figure 4-3: INDEX PART No. NO. NO. PARTNAME REQD. '505050-07 Control Head 1005847 “Connector 1 2 078202 Swen neulator 1 3 020869 Micro Swich 1 4 020778 Micro Switch 4 5 052955 Flanged Bearing 2 8 056517 Forward Reverse Decal 1 7 050633 Hox Locknut, 2-55, 2 8 050634 Hox Locknut, 4-40 2 9 060573 Dowel Pin, 14x 1516 2 10 06092 RollPin, tia x 1-1/6 2 41 061016 Rollin, 14 x2 2 12 06120001 Spiol Pin, 916 x1 4 13067416 Pan Ha. Screw, 6-32 x V2 4 14068189 Rd. Hd. Scrow,4-4021-718 2 15 069462 Slotted Flat Hd. Scrow, 6-32 x3/4 2 46 069463 Slotted Flat Hd. Sorow, 2 47 060478 Philips Fat Ha, Screw, "14-20 x34 ‘ 18 069715 Sockot Flat Hd Scrow, 14-20 x34 12 070486 Round Hd, Slotied Machine Scrow 20 072400-01 HexHa. Siotied Screw, 6:92 x172 21 072615—-Pan Hd. Screw, Thread Cutting 22 072461 Socket Set Screw 23 o7a7i1, ‘Spacer 24 076088 © Relum Spring 25 075510 Compression Spring 28 077007 Washer INDEX PART NO. 4. Install insulator (2) and belly-button switch (3) and secure with screws (19) and locknuts (7) ©. Adjust belly-button switch (paragraph 4-14). Replace a defective high speed cutout switch (44) as follows: a. Disconnect the battery. Remove screws (52) and top cover (54). c. Remove screws (53) to release cutout switch (44). 4. Tag and disconnect electrical wires from cutout switch (44). €. Connect electrical wires to new cutout switch (44), ‘as noted during removal. f. Install cutouts serews (52). (44) and secure with Install sop cover (54) and secure with screws (52). ‘h, Connect battery. NO, PARTNAME REA 27 077204 Split Lock Washer #6, 402827 Shaft 402828 Cap 402830 Bottom Access Cover 402834 Tube. 402838 Spacer 402837 Bracket 402830 © Tubo 40ze40 Cam 402861 Handle Guar oa Pad '504538-01 Switch Wiro Assembly 505052. Switch Bracket ‘900272 Control Lever 1800273 Control Handle 300274 Cover 020697 Pushbutton Switch 020699 Cutout Switch, High Speed RasTSeeseREsRseBE anne ete eam ean sen ss awman BB 45 020776 Hom Pushbution Switch 46 © 023171 Wire Hamoss Assemby 47 056818_—_High Speed Decal 43 056519-03 Lin Decal 49 056519-04 Lower Decal 50 056624 Horn Decal 51 067615 Pan Hd. Scrow, 6-92 x 14 52 067616 Pan He. Scrow, 6-32 x 12 53068190 Philips Pan Hd. Screw. 54 402833 ‘Top Cover 55 402842 Switch Plato PTw-40|. SEE SUPPLEMENT 220 FOR 2. REFERTOSUPPLEMENT207 3. SEE SUPPLEMENT 187 FOR TRANSISTOR SPEED CON- ‘TROL TRUCKS SERIAL NUM- BER 334631 AND HIGHER FOR TRANSISTOR SPEED — TRANSISTOR CONTROL TRUCKS SERIAL NUMBER 332493 TO 334690 i ar USED ON TRUCKS SERIAL NUMBER 332483 AND HIGHER Figure 4-3. Control Head Assembly, SN 332483 and higher PTw-40 455. Replace a defective pushbutton switch (43 or 45) as fol- lows: ‘a. Disconnect the battery Remove screws (52) and top cover (54) ‘c. Remove screws (13) and bottom cover (30). 4. Remove screws (15 and 16) to release switch plate (55), . Remove screws (51) to remove Tift or lower switch (43). f Remove nut and washer from back of hom: switch (45) to remove from switch plate (55). & Tag and disconnect electrical wires from defective switch, h. Connect wires to new switch, as noted during. removal i. To instal lift or lower switch (43), position on back of switch plate (55) and secure with screws (51). J. To install horn switch (45), position on front of switch plate (55) and secure with it's washer and k. Install switch plate ($5) and secure with screws (15 and 16). |. Install top cover (54) and secure with screws (52). ‘m. Install bottom cover (30) and secure with screws (13). 1. Connect the battery. Steering Arm (Figure 4-8) 1. Steering Arm Retum Spring Adjustment ‘The tension on the steering arm retum spring should al- low the steering arm to return gently to the upright posi- tion. Excessive tension on the steering arm return spring will cause the steering arm to snap up and may ‘cause damage to the electrical cable, brake linkage or the spring itself. If the steering arm does not return fully, check for binding in the brake linkage or wiring hhamess before making any adjustments. If they do not bind, refer to Figure 4-4 and proceed as follows to ad- {ust the steering arm retum spring tension, CAUTION: The steering am will have a tendency 10 fall when the tension on the return spring is released. ‘a. Hold the steering arm in upright position and make sure the arm cannot fall. b. Insert a 5/16 Allen wrench through hole in bottom, of steering arm and loosen screw (15). The spring 46 tube will rotate counterclockwise when screw is Toosened. c. With a pair of vise-grip pliers, grip the flat surfaces. of spring tube assembly (2) and rotate clockwise 180 degrees. 4d. Hold spring tube assembly in rotated position and tighten screw (15) to secure. ‘eCheck the spring action by lowering the steering arm and retuming it to the upright position two or three times. £. If necessary repeat steps a through e, increasing or decreasing amount of rotation of the spring tube as- sembly until steering arm retums gently to full upright position. 2. Replacement. The steering arm return spring is replaced while the steering arm is in the upright position. a. Disconnect battery. CAUTION: The steering arm has a tendency 10 fall downward when the tension on the return spring is released. b. Hold steering arm in upright position and make sure the arm cannot fall. . With a piece of chalk or crayon, draw a straight line from center of spring tube assembly (2) into pivot cap (3), marking radial position of tube to facilitate reinstallation. 4. Insert 5/16 Allen wrench through hole in bottom of steering arm and loosen screw (15). CAUTION: Unless properly supported, steering arm will drop out of pivot cap when spring tube is removed. e. Puta block under steering arm at pivot cap. £. With a pair of vise-grip pliers, grip the flat surfaces of spring tube assembly (2) and slowly pull it free from the steering arm, pivot cap and tube clamp. NOTE: Steering arm retum spring (1) will remain inside the spring tube assembly. g. Remove steering arm retum spring (1) from spring tube assembly. If spring is severely jammed and ‘will not come loose, use punch and drive the 1/4- inch diameter roll pin into the tube. Save pin for re- use, Remove the spring. Tap roll pin back into place. PTW-402 INDEX PART NO. _NO, 1 975060 2} sots71 a! anzass 3 052876 5 o7377 By 25902 74 285003 8} 077210 8+ 059426 10" 00208 M1 os29z 12", 800266 00279 12° 060478 44 023120 15065560 16 401127 PTW-40 a Figure 4-4, Steering Arm No. INvex PART NAME EOD. NO. ‘Spring, Return 1 7 ‘Spring Tube 1 18 Phvot am REF 19 Bumper 2 20 Screw, Pan Hd, 10:92 x24 3 at Spring Pin 1 23 Spring Pin 1 2 ‘Washes, Lock, Spit, 5/16 2 25 Nut, Hox 516-18 2 at Tube Clamp 1 2et Flanges Bearing 1 2 ‘Steering Arm 1 20 ‘Steering Arm 1 Et ‘Screw, Fat Hd, 14-20 x 3 2 32 Gora Cable 1 3 ‘Screw, Socket Hd, 716-14x2-1/4 1 3 ‘Spacer 1 35 pant NO. 065481 (052925 1503996 ‘60417 402459 ‘504364 (060300 (056200 (061050 ‘061006 059421 077208 077031 402982 ‘059480 oai7ie 402452 PART NAME ‘Sorow, Socket Hd, 114-201 Flanged Bushing Brake Rod otter Pin, 3732 x 314 Pivot Cap Cover ‘Cable Clamp and Nut Assembly Glovis Fin Clovis Foll Pin, 918 x 1-14 Fell Pin 14 x 1-14 Nt, Hox, 174 Lockwasher, 1/4 Washer Stop Scrow, 14-201 ‘Snap fing, 518 Pin + Included in Return Spring Kit, P/N 901325. * For trucks prior to S/N 332483. * For trucks S/N 332483 and Higher. No. REQD. 2 REF Aer REF a7Lubricate the ends and the outer surface of the new steering arm retum spring with «lithium base generil purpose grease, Insert spring into spring tube assembly and press in, making sure that one spring loop eye fits over the 3VB-inch roll pin at the closed end of the spring tube assembly. Slide spring tube assembly into pivot cap (3) and steering arm (12) through tube clamp (10) and through loop of electrical cable. Refer to Figure 4-5 for internal view of steering arm with return spring installed, Align radial position of spring tbe assembly in accordance with line drawn in step c. Slowly rotate spring tube assembly a few degrees each way until the steering arm return spring snaps into place over spring pin (6, Figure 4-4): then tighten serew (15). Remove block from under steering arm. m. Refer to paragraph 1. step e and, if necessary, ad- 6 9, 10. 48 just the tension on steering arm return spring, Reconnect battery Electrical Control Cable Removal or Replacement (Figure 4-5). Disconnect battery. Remove 4 screws (I1) that fasten control head as sembly to steering arm. Disconnect the exposed connector (5) Remove cable clamps (1, 2) and loosen Toop of cable that is around the spring tube assembly (3). Remove pivot cap cover (10), If cable is to be reinstalled, use pin extractor (Big Joe PIN 900750) to remove contact pins from connector (5). tagging each pin with location in connector. If a new cable is {0 be installed cut off connector (5) from end of cable. Pull loose end of cable up. and let it extend through pivot cap cover opening, Disconnect connector (7) ftom contactor panel har~ ness. Remove from (7) the wires in pin locations 3, 7. 8.1] and 13, Remove and tag remaining wires from connector (7), oF if replacing a bad cable cut connec tor (7) off the bad cable. Draw the cable out through the pivot cap opening. Remove the pins from connector (5) on the new cable, tape the wire ends together. u NOTE: Grease the new cable with a lithium base grease or silicone spray. ‘The deadman switch is on the brake linkage. ‘The wires connected to the pin numbers 3 ‘and 8 on the connector (7) are wires that go to the deadman switch. The wires connected to pin numbers 7, 11 and 13 on con- nector (7) are wires that go to the hom, pump solenoid and the lowering valve. Feed the cable through the grommet from the contac tor panel side of the frame. Then fee it through the collar (2, Figure 4-10) into the pivot tube. Leave con- nector (7, Figure 4-5) exposed approximately 3 inches by the panel. Push the cable down the pivot tube and towards the pivot arm. 13, Pull the connectorless end of cable under spring tube ‘assembly (3) and out the opening atthe elbow. 14, Eliminate cable slack in pivot tube: then secure cable with cable clamp (1), 15. Loop cable aroung spring tube assembly as il- lustrated (Figure 4-5) and push connector end of cable into steering arm. CAUTION: Improper cable loop adjustment will damage the cable. IF oo tight, the cable will tear when the steering arm is in the up posi- tion, If too loose, the cable will buckle or be pinched when the steering arm is in the down position, 16, Pull the cable until the cable is wrapped firmly ‘around the spring tube assembly (3). Slack off ap- proximately 1/2 inch and secure the cable in this posi- tion with cable clamp (2). 17. Work steering arm up and down a few times to as- sure that the electrical control cable is not binding. 18, Reinstall wires into locations 3, 7, 8 11 and 13 in connector (7) as per wiring diagram. (Figure 4-24.) 19, Reconnect connector (7) to panel hamess. 20. Wipe off excess grease or silicone spray from ex- posed parts ofthe cable. 21, Reconnect wires into connector (5). Plug con- rector (5) into receptable, (34 Figure 4-2) or (46, Figure 4-3). 22. Reinstall the control head assembly, pivot cap cover, ‘and base access cover. 23, Reconnect battery, PTW-408 4 L- \ ---\— A ol Y L | ner - ener) 5 STEERING "aR | Figure 4-8. Electrical Control Cable Replacement INDEX PART No. INDEX PART NO. NO. PART NAME: REQD. NO. NO. PART NAME 1504384 Clamp, Cable REF 8 005826 Pin, Connector 2 508364 Clamp, Cable REF 9 402455 Arm, Pivot 3 507371 Tube Assembly, Spring REF 30 402459 Cap 4 023129 Contol Cabo, Elctcal REF 1% 065481 Sorow, Cap, Socket Hoad 5 005640 Connector, Female 1 32 508714 Pwol Tube & 005542 Pin, Connector 2 48 800176 Housing, Transmission 7 005452 Connector. Male 1 14 402452 Pin PTW-40 — 2iner) No. REQD. 2 REF REF REF AEF AEF REF 4942, BRAKE SERVICE. 424, Brake Adjustment If the mechanical brake does not begin to hold, when the steering arm is raise or lowered into the lightly shaded area in figure 2-3, adjust as follows: 1 2. Disconnect the battery. Jack up the truck so the drive wheel is off the ground, then securely block the truck to prevent slipping. Remove the service cover. Secure the steering arm assembly in a position that is in either lightly shaded area shown in figure 2-3. Adjust brake on trucks prior to serial number 333080, as follows: a. Loosen brake adjust nut (Figure 4-6), and the wo brake switch adjust nuts. b. Spin drive wheel by hand and position the brake rod by adjusting the brake adjust nut until you feel a noticeable drag. c. Resecure the steering arm in drive position and. spin the drive wheel to be sure there is no drag. 4, Adjust deadman brake switch, paragraph 4-2-2. eaace ——| Figure 4-6. Brake Adjustment, Prior to S/N 333080. 410 Adjust brake on trucks serial number 333080 and higher, as follows: e Loosen the two brake switch adjusting nuts (Fig- ure 4-6), Remove the cotter pin (1, Figure 4-7), then slide the rod (2) into the brake lever (3) far enough 10 pall the link pin (4) out ofthe lever (5). ‘Tum the link pin (4) to make the adjustment Slide the link pin (4) back into the lever (5), but 4o not insert the cotter pin (1) at this time. Spin the drive wheel by hand to check brake ad- justment. If there is no drag, go to step f. If there is noticeable drag, go to step h. Disconnect the link pin (4). Repeat steps ¢ through e until adjustment is cor- rect providing noticeable drag. Install the cotter pin (1). ‘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. ‘Adjust deadman brake switch, paragraph 4-2-2. |. Lower the truck and install the service cover. Connect the battery. re 47, Brake Adjustment, S/N 333080 & Higher. PTW-4042:2. Deadman Brake Switch Adjustment. 1. Remove the restrictions from the steering arm and let the arm retum to the upright position. 2. A properly adjusted deadman brake switch must be ac- tivated when steering arm is in upright position, remov- ing power from central circuits. 3. Adjust switch by sliding up and down in the slots of ‘mounting bracket, making sure the brake activates the switch but does not fully depress the switch plunger. 4. Tighten the brake switch adjusting nuts (Figure 4-6), securing the switch in adjusted position, 4-2-3. Replacement of Disc Brake Parts, Prior to SIN 333080 (Figure 4-8.) 1. Block the wheels to prevent the truck from rolling. 2. Secure the steering arm down from its park position so thatthe brake is disengaged. 3. Remove service cover. 4, Remove outer snubber (24), 5. Loosen hex nut (19). then remove two studs (15) and inner snubbers (24) 10 release brake pads (13) and spring (18). 6. If brake pads and springs do not fall free, slide brake pads out from end of bracket (12). 7. Insert replacement brake pads in clamp assembly, one pad on each side of dise (16) with lining towards the disc, install springs (18), and secure pads, springs and clamp with two studs (15). Be sure snubbers (24) are fon studs to hold bracket (12) in place. 8. Release steering arm. 9. Refer to Paragraph 4-2-1 and adjust brake, PTW-40 MOUNTING PLATE Figure 4-8, Brake and Linkage, Prior to SIN 333080 INDEX PART No. NO. NO. PART NAME REOD. 1 S087i3 Brake Rod Weldment 1 2 060817 Coter Pin 5 3 509524 Brake Lover 1 4 060821 Clevis Pn 1 5 050628 Look Nut 1 & 800188 Brake Rod 1 7 059108 Flanged Bushing 1 8509523 Bracket 1 10 069877 Scrow,HexCap Hd, 1420x518 3 11077209 Washer, Lock, Spit, 3 (052867 Brake Calper Assembly 1 12, 052863 Bracket 1 13t 059859 Pad 2 14) 052866 Lever 1 15 400701 stud, 28-16 2 16 052885 se AEF 17 400808 Pin 1 18+ 075070 Spring 2 19) 058425 Nut, Hox, 5716-18 2 20 o77011 Washer Flat, 5/16 3 21 060320 Clovis Pin : 22 059109 Flanged Bushing 2 23111104 Upper Pivot Pato 1 2a 402274 Smubber 4 + Included in Brake Pad and Spring Service Kit P/N 901327. an4-2-4, Replacement of Caliper Brake Parts - ‘SIN 333080 and Higher (Figure 4-9). 1. Disconnect the battery 2. Block the wheels to prevent the truck from rolling 3. Secure the steering arm down from its park position, so the brake is disengaged. 4, Remove the service cover. 5. Remove the cotter pin (2, Figure 4.9) from the link pin (17). 66. Slide the rod (16) with link pin (17) far enough into the brake lever (15) to pull the Tink pin out of the lever (29). 7. Remove the two nuts (19) and lock washers (31). 8. Carefully pull the bolts (20) just enough to clear the mounting blocks (11) while holding the remaining pans of the disc brake assembly (18) together, then remove the assembly. 9. Remove the bolts (20), springs (22), spacers (21), and brake pad (23). 10. Remove the C-ring (24), washer (25), spring (26), bracket (28), lever (29), and washer (30) from the brake pad (27). a2 Te 17, 18, 19. 2. Discard the springs (22 and 26) and brake pads (23 and 27). Replace them with new parts. Assembly the washer (30), lever (29), bracket (28), spring (26), washer (25) and C-ring (24) to the brake pad (27). ‘Assembly the brake pad (23), spacers (21), and springs (22) to the two bolts (20). ‘Align the bolt holes in the bracket (28) and brake pad (27), then slip the bolts (20) through the holes ‘and hold the assembled parts together. Insert the blocks (11), bolts (20) through the mounting ‘Assemble the lock washers (31) and nuts (19) to the bolts (20). Slide the link pin (17) into the lever (29) and secure the link pin with the cotter pin (2). ‘Adjust the brake as described in procedure 4-2-1 Install the service cover. Remove the restrictions from the steering arm. Connect the battery. PTw-40INDEX PART NO. NO. 1 0s3t09 2 05087 3053106 4 tn08 5 060320 8 06032 7 s0a7i3 2 509523, 9 o77209 to 083482 41 a0ave2 12 063477 33 400804 44 o7ans 15 505232 16 403179 PTW-40 Figure 4-9, Brake and Linkage, S/N 333080 and Higher. PART NAME Lock Bushing otis Pin, 3782 x24 Flanged Bushing Upper Pivot Pate Clovis Pin Clovis Pin Brake Rod Weldment Bracket lock Washer, spit, 14 Serow Mounting Block ‘Screw, Cap, Hex Hd, 18-20 x 518 Pin Washer, Flat, 5/16 Brake Lever Foo No. REQD. INDEX NO. 7 18 18 20 2 2 2 24 25 Fy 2 28 2 20 3 EH Pant NO. 900188 052821 050421 901189 1901190 sore ‘901188 901198 901197 901196 sor1s2 901195 sor198 901193, 07208 505256 PART NAME ink Pin ise Brake Assombly ‘Nut Bot Spacer Spring Brake Pad CRing Washer Spring Brake Pad with in Bracket Lever Washer Lock Washer, spt, 1/4 Dise, Brake NO. REQD. 4434-3, TRANSMISSION, DRIVE MOTOR AND. PIVOT TUBE ASSEMBLY. ‘Transmission and Pivot Tube Assembly Removal. 1. Disconnect ely. 2. Block load wheels, 3. Remove service cover: 4. Unscrew the pivot cap cover (7, Figure 4-10) from the pivot arm and remove. 5. Label and disconnect wires. 6. Disconnect brake rods by removing cotter pin. 7. Remove steering assembly. 8. Support the transmission assembly and remove the 1wo snap rings (8) and drive the pin (10) from the pivot 9. Lower the pivot tube weldment (5) and transmission down and out ofthe truck Figure 4-10, Pivot Arm Assembly WNpex PART No. NO. NO. PART NAME REQD. 1 800265 Bushing, Pvot 2 2 402450 Collar 1 3 051146 Trwust Boating 1 402451 Spacer 1 5 504714 Prot Tube Wolgment 1 6 069710 Scew 4 414 INDEX PART No. NO. NO. PART NAME REQD. 7 402469 Cap ‘ 8 061716 Snap Ring, 58 2 9 402855 Am 1 30 402452 Pin 1 43505283 Transmission Assy (See Fig 4-12) AEF PTW-40‘Transmission Initial Disassembly. Disconnect battery. Securely block load wheels. 3, Remove service cover. 4. Remove magnetic drain plug (19, Figure 4-11) and drain transmission, 5. Tum steering arm to gain access to cover (43). 6. Remove fourteen screws (45) and lock washer (46). holding cover (43): then remove cover, 7. Remove and discard gasket (42) 8. Remove thrust washer (29), gear (28), and key (51). NOTE: When reassembling, be sure to replace the gasket and reinstall the magnetic drain plug before refilling the transmission with trans- mission oil, Transmission holds 1-1/2 quarts, oil C. Drive Axle Removal. Perform Steps I through ¥ in initial transmission disas- sembly. Raise the rear of the truck using jacks or other suitable ‘means so that drive wheel is 6ff floor PTW-40 3. Remove snap ring (41, Figure 4-11), gear (40), and key (9), then pull out shaft (33) and wheel (13) ‘Washers (34 and 35) and seal (36) will all ree. NOTE: During reassembly be sure all. washers spacers, and the seal are reinstalled in proper sequence as shown in the illustration D. Drive Motor/Brake Assembly Removal. LL. Perform the intial disassembly. steps 1 through 8. 2. Remove the cotter pin that fastens the brake rod to the brake caliper lever. 3. Make sure the four cables 10 the drive motor are properly labeled Al, A2, FI, and F2; then disconnect the cables from the drive motor. 4, Remove the four bolts (2, Figure 4-11) 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 single 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 properly sequenced on armature shaft and that dowel pins in motor mounting plate are aligned with corresponding holes in trans- ‘mission housing, aisINCLUDES ITEMS 17 NOTE: ITEM 16A, GEARBOX ASSY THRU 52. Figure 4-11. Transmission PTw-40 416Parts List for Figure 4-11: INoex NO. a tt 0 n 2 13 4 5 16 16a ” 18 19 2 24 pant NO. 505233 16036 604s, 053857 77210 800185 403181 sis 057908 052888, 505256, 51200, oazis2 00603 agian 073517 502674 52764 059495 soars 901962 057237 ‘06097 ‘ozsa02 051206 ostz02 306808, oreo 057258 osizi6 PTW-40 No. INDEX PART PART NAME REQD. NO. NO. PART NAME ‘Transmission Assombly 1 2% 051208 —Bearing-Neede Thust ‘rive Molo (See Figure 412) 1 27 057256 © Gear and Shaft. Orive Molo (See Figure 413) 1 28 57241 Gear Bolt, 516-10 x 7-7/8 4 29053031 ‘Thrust Bearing Washes, Spit, 518 4 30 051204 = Boarng Motor Pate 1 31 051203 «Bearing Motor Pate 1 32 051207 ——_—Bearing-Neodto ust Screw, Cap SocHs, 1032x1 3 3a sort Shatt Koy 1 34 051217 —Trvust Bearing Dice Assy 1 35 053028 ©—Thvust Boaring Diso Assy 1 36 o7asi6 «Seal Bearing 1 37 051215 Bearing O-Ring, 1.3 in. a 1 38074707 Spacer Motor Bearing Housing 1 39057008 «Key O-Ring, 1.5 in. dia. 1 40 057242 «= Gear Seal 1 41061731 ‘Snap Ring, Ext, 1-3/6 Whoo! and Hub Assy (STD) 1 42 03stis Gasket Bot 5 430018 §=— Cover Hox Hd Screw, 14-20 x 172 2 4060609 Pin Pivot Tube and Plate As REF 45 063482 Scrow, 14.20 1-414 Gearbox Assembly, Transmission 1 48 © 077209 «= Lack Washer, 1/4 ‘Gear 1 47025310 «Plug Fol Pin 1 48076702 Vert, Transmission Plug 1 49800176 Transmission Housing Beating Needle Trust 2 50 057238 «Gear Bearing 2 51 057009 Key. ‘Spacer 1 52 057257 Garand Shaft Gear 1 53077208 Lock Washer, 916 1 54 060609 Pin + Drive Motor used on trucks prior to S/N 333708. +t Drive Motor used on trucks S/N 333706 and higher. $ Foruse on trucks prior to S/N 333080. 44 For use on trucks S/N 333080 and Higher. No. AEQD. 47USED ON TRUCKS PRIOR Figure 4-12. Drive Motor, Prior to S/N 333706 ‘TO SIN 333706 e omy 9 INDEX PART No. NO. NO. PARTNAME REQD. (016036 Drive Motor (MHC-4008) REF 1 900446 Field Coil Package 1 2 900487 Armature 1 3 900449 —_Commutator End Bearing 1 900450 Brush (Set of two} 4 5 900451 Brush Spring (Set of wo) 1 E. Drive Motor Servicing. The drive motor exposed surfaces should be cleaned at least once a month to assure proper cooling of motor. Use an air hose to blow dust off of motor surfaces. If the truck does not run and the drive motor is at fault, inspect brushes (4, Figure 4-12 or 4-13) and commutator (on armature). Replace brushes if they are wom. Clean com- ‘mutator 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 battery 2. Make sure the four cables to the drive motor are properly labeled Al, A2, Fl, and F2; then disconnect the cables from the drive motor. 3. Remove the four screws holding the motor mounting 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. as INDEX PART No. NO. NO. PART NAME REQD. 900452 Commutator End Head 1 7 900500 Terminal Stud Package 1 8 077209 Lock Washer, /4 4 8 900516 Fistor Hd Scrow, 1092x584 10 900499 Brush Plate Assy 4 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 armature will line up with bushing in transmission; then tap motor mounting plate in place and fasten with four 4-4, BASE, FRAME AND FORKS. A. General. The base and frame package of the truck includes the covers, decals, forks and load wheels. Removal and replacement of covers and decals is straight- forward and does not required detailed information, see Figure 4-14, Make certain that all decals remain on the truck and are legible. If decals are damaged or missing, they must be replaced. See DECALS, Paragraph 1-6. PTw-40USED ON TRUCKS ‘SIN 333706 AND HIGHER 9 Figure 4-13. Drive Motor, Used on S/N 333706 and Higher. INDEX PART No. NO. NO. PART NAME REQD. 016045 Dive Motor REF 1 901266 Fietd Col Set 1 2 901285 Armature 1 3 901266 Commutator End Bearing 1 900450 Brush (Se of two} 1 5 900451 Brush Spring (Sot of two) 4 8 80'267 Communtator End Head 1 7 901268 Terminal Ki 1 8 Lockwasher, 14 4 oo Filisior Head Scrow, 10-92 x34 4 10 901269 Brush Holder 1 " Pole Shoe Screw, 98-1612 2 PTW-40 a9INDEX PART NO. NO. un % 8 1 18 6 7 4-20 soe7i7 402301 070877 077209 077031 sears + tt 056631 056596-09 056595 70477 77208 77031 ‘02464 071378 (077208 504716 402458 (056613 PART NAME EOD. Cover Weldment 1 Soundprooting 1 Screw, 114-20 x 58 4 Lock Washer, 1/8 4 Washoe 4 Decal, Door, Big Joe ; Decal, Door, 81g Jos 3 Decal, inseri PTW-40 4 Casting, Logo 4 ‘Scrow, 1/420 x 5 4 Lock Washer, 114 4 Washer 4 Cover, Right Hand 3 Scrow, 10-32% 1/4 4 Lock Washer 4 Cover Weldment 1 Pad 1 Decal, Oper: Inst, PTW 40 1 impex NO. 8 1% 2 21 2 2 28 23 28 a Ea Ey 30 a |. Base, Frame and Fork Section PART NO. 05651 (066050 056499 1402099 (055700 NA sess4 o2sri3 61000 52300, ostt02 53000 53001 PART NAME. Decal, Power Connect ‘Screw, 3132 % 1/4 Decal, No Rising Spacer Adhesive Nameplate Decal, Caution Fiting, Grease Pin, Rol, 14 x 578 Polio Bearing, Roller Washer, Thrust, 332 Washer, Thr Washer, Thrust, 532 Washer, Trust, 316 Grease Fiting Fork Secton Weldment * For fork section details, see Figure 4-15, on trucks prior to S/N 317949; or Figure 4-16, for trucks S/N 317949 and Higher. + Used on trucks prior to SIN 330008. ‘tt Used on trucks S/N 330008 and Higher. Bs a ABBRBecuw a eBeawe PTW-40USED ON TRUCKS PRIOR TO SIN 317949 INEX PART NO. NO, 1tt 061200-02 2it 40zaaa B4t 077008 att sotese 5) 508707 5 052948-03 7 aozase 8 081200-02 9 077063 10 061200-01 1 402431-01 tt PTW-40 Figure 4-15. Fork Section Details, for Trucks Prior to S/N 317949, No. INDEX PART PART NAME REQD. NO. NO. oll Pin, 316 x 1-1/2 2 6 Shaft 2 16 Washer 4 47075085 ‘Wheel Assy, Poly 2 38 081200-01 Housing Weldment, Wheel 2 39 402431-02 Bearing 2 20. 061200-01 Shat, Prot 2 ait anenes Rol Pin 2 22! 504708 Flat Washer 20 me RollPa, 316 x1 2 26 061200-01 Shaft 2 25 40243102 Pull Rog 2 et s0498s Beating REF ee Coupler 2 PART NAME Rt Fog End Weldment ‘Bearing ‘Spring Extension Poli Pin, 16x 1 Shaft Poll Pin, 316 x1 Shat, Prot Rolie Assy ‘Bearing oll Pin, 316 x1 Shaft Pivot Weldment Bearing Trucks prior to SIN 317949 had welded pull rods. These welded pull rods are no fonger available. Order the appropriate adjustable pull rod kit from Table 4-1. Trucks were originally equipped with flanged bushings. ‘Order kit 901037 to update your truck with the new bushings. + Replace both index number 21 and index no. 26 if replacing either. Included in Load Wheel & Axle kit 901330, kit services 1 side. Two kits required for complete truck. pore 4-21USED ON TRUCKS ‘SIN 317949 AND HIGHER Figure 4-16. Fork Section Details, for Trucks S/N 317949 and Higher. INDEX PART No. INDEX PART NO. NO. PARTNAME: EOD. NO. NO. PART NAME Fork Backrest Assembly 5 Pull od with Spring Retainer, No. REQD. 2 1 tt o61200-02 Roll Pins ane e172 2 ‘Adjustable 2tt 402433 Shah 2 16" 052048-01 _ Bearing 2 3tt 077008 © Washor 4 17 075085 Spring Extension 4 44F 501692 Wheel Assy, Poly 2 18 061200-01 oll Pin, 316% 1 2 5) 504707 Housing Weldmert, Wneet 2 39 402431-01 Shah 2 6 052088-03 Bearing 2 20 061200-01 Roll Pin, 16 x1 2 7 402432 "Shalt, Pivot 2 21 402825 Sha, Pivot 2 @ 06120001 Roll Pin 2 22 504708 llr Assy 2 9° 077083 Flat Washer 20 23 052048.01_ Beaiing 2 40 061200-01 Rll in, 3/16 x1 2 24 061200-01 Roll Pin, 216 x1 2 41 402491-01 Shalt 2 25 402831-02 Shaft 2 2 : Pull Rod, Adjustable 2 26 504085. Pwvol Woldment 2 13 os2948.03 "Bearing 2 27 052848-02 Bearing, ‘ 14 402051 Coupler 2 2 osa4ag Nut 2 2 29 OTT215 Washer * Refer to Table 4-2 for part numbers. * Parts listed are for S/N 319661 and higher. For trucks prior to SIN 319661 order kit 901037. One kit services entire truck. +t Included in Load Wheel & Axle Kit 901330, kit services 1 side. Two kits required for complete truck. 4-22 PTW-40B. Load Wheel Replacement. |. Raise the forks. 2. Block the drive wheel to prevent the truck from roll- ing, 3. Jack the forks up high enough to lift the load wheels ‘ff the floor and block securely under the tips of the forks. 4. Drive the roll pin (1, Figure 4-15 or 4-16) from the shaft (2), and pull the shaft out of the clevis, freeing, the wheel (4). C. Pull Rod and Pivot Roller Replacement. |. Lower forks completely. 2. Disconnect battery. 3. Remove cylinder access plate. 4, Disconnect pressure hose from cylinder. ‘5. Raise fork section 3” high with a hoi 6. Remove cylinder bolts and cylinder. 7. Lower fork section to floor. 8. Raise power section with hoist clear of the fork see- tion. CAUTION: Power section is heavy. Use care while securing power section in order to prevent injury. 9. Drive the roll pin (8, Figure 4-15, 4-16) from the load Wheel housing shaft (7), and remove the shaft and spacer washer from the forks. 10, Move to the back of the forks and remove the roll ppin (20) from the pivot weldment shaft (21, Fig- ture 4-15, 4-16). Drive the shaft out to the inside using the hole in the outside of the backrest stanchion for access to the shaft. 11. Disengage the extension springs and lower the pull rods. 12, Drive out the roll pins from the pivot weldment and load whee! housings and remove the shafis (16 and 6) from the housings. PTw-40 ‘Table 4-1. Adjustable Pull Rod Kit Numbers Kit No. 901035 901035-01 901035-02 901035-03 901035-04 901035-05 901035-06 901035.07 901035-08 :901035.09 NOTE: One kit services pull rods and coupler for entire truck, 13, Remove the pivot roller by driving the roll pin (24) from the pivot weldment and removing the pivot roller shaft (25) from the pivot weldment. 14, Connect rod (12) to wheel housing and attach hous- ing to frame; then clamp wheel housing in place. 15, Spray all threads with silicone lubricant. 16, Install nut (28) and washer (29) on to rod (12). 17. Thread coupler (14) approximately 1-3/4" onto rod (12) 18, Thread rod (15) approximately 1-3/4" into coupler and connect rod to pivot weldment (26). NOTE: A 16.75" dimension must be set up on back- rest prior to locking down jam nut. Use a spacer to hold this dimension. See Fig- ure 4-17, 19, Adjust coupler (14) to hold the 16.75" dimension on the backrest and tighten nut (28). 20, Reassemble in reverse order. D. Pivot Shaft and Pivot Weldment Replace- ment. (On all PTW series lift trucks Serial Number 321244 and higher, pivot shaft 402825 replaces the pivot shaft 402432 at index location 21, Figures 4-15 and 4-16, and pivot ‘weldment 504985 replaces pivot weldment 504709 (26, Figures 4-15 and 4-16). When replacing the pivot shaft or weldment on trucks Serial Numbers. prior to 321244, replace them both. 4-231. Raise the complete truck with a hoist or a jack so the underside of the forks are accessible. 2. Disconnect the battery 3. Move to the back of the forks and remove roll pin (20) from pivot shaft (21), 4, Drive the pivot shaft out towards the inside of the truck using the hole on the outside of the backrest stanchion for access to the shaft. Remove any flat washers (9). ‘5. Remove roll pin (18) from shaft (19), 6. Drive shaft (19) out towards the inside of the truck. Remove any flat washers (9). 7. Remove pivot weldment (26) from rod end weld- ‘ment (15). 8. Remove pin (24) from shaft (25), 9. Drive shaft (25) from pivot weldment. Remove any flat washers (9) and roller assembly (22), 10. Check all parts to be reassembled for cracks or exces sive wear and replace any unusable parts. NOTE: Use No. 20 engine lube oil to lube all bear- ings and pivot points when reassembling. NOTE: When reassembling use additional washers (9) where necessary for shimming, 11. Check that bearings (23) in roller assembly (22), bear- ings (16) in pull rod (15) and bearings (27) in fork are not damaged, Replace bearing(s) if damaged, 424 12, Reassemble in reverse order. 13. Adjust pull rod per following steps. NOTE: Be sure to check adjustment on both pull rod assemblies. 14, Clamp wheel housing in place as shown in Fig- ure 4-17. 15. Measure 16.75" dimension as shown in Figure 4-17. If measurement is within tolerance, pull rod does not need adjustment, 16. If adjustment is required, loosen jam nut then adjust coupler for required 16.75" dimension, 17. Lock coupler in place by tightening jarn nur. 18, Remove clamp. 19, Repeat adjustment on remaining pull rod assembly. 20, Lower truck. 4-5. ELECTRICAL. ‘A. Battery Removal and Replacement. Batteries are removed from the top of battery compart- ‘ment using the handles mounted on the battery. CAUTION: Batteries are heavy, a hoist and sling should be used to prevent injury or battery damage. Unplug the battery quick disconnect and remove the con- rector cable between the two batteries. Hoist the batteries ‘out one at atime. PTW-40re e vam NUT IMPORTANT MUST MAINTAIN 1675.02 SET UP IM. PRIOR TO. LOCKING DOWN ‘JAM NUT, USE SPACER TO HOLD THIS DIMENSION, | coupLen Figure 4-17. Backrest Dimension Set-Up ‘Table 4-2, Additional Part Numbers for Figure 4-16. FORK BACKREST PULL ROD NUMBERS FORK LENGTH| ASSEMBLY NUMBER | _ WELDMENT (TEM 12) (ITEM 15) 48" '504725-01 804705-01 504762-01 504763-01 4s" '504725-02 504705-02 504762-02 504763-01 4a" '504725-03 504705-03 504762-03 504763-01 4" '504725-04 504705-04 504762-04 504763-01 40" 504725-05 504705-05 504762-05 504763-01 38" 504725-06 504705-08 504762-06 504763-01 36" 504725-07 504705-07 504762-07 504763-01 3a" '504725-08 504705-08 504762-06 504763-02 32" 504725-09 504705-09 504762-07 504763-02 30" 504725-10 504705-10 504762-08 504763-03 PTW-40 NOTE: This Table is for trucks S/N 317949 and higher. Refer to Figure 4-16 for trucks prior to S/N 317949. 425INDEX NO. 4-26 PaRT NO. saz o77ait 69406 077208 ‘005450 508727 056113 508726 003149 Not Pictured — 4 Adhesive-Backed Battery Mou PART NAME Nut, Hex, 98 Lock Washer, 3 Serow, 14-20 x2-1/4 Washer, Lock. 14 Handle, Pull Figure 4-18. Electrical Components No. REQD. INDEX NO. 10 " 2 3 4 8 6 PART NO. os7sis 023135 ‘005405 (020728 504720 77064 04721 Pads PIN 402543 PART NAME. Grommet Cable Assy Rott, Sain ‘Switch, Dead Man Eloctical Panol Assy ‘(See Figure 419) Washer ‘Connector, Battory PTW-40|. SEE SUPPLEMENT 220 FOR TRANSISTOR 2. SEE SUPPLEMENT 187 FOR TRANSISTOR ‘SPEED CONTROL TRUCKS SERIAL NUMBER: ‘SPEED CONTROL TRUCKS SERIAL NUMBER 338608 AND HIGHER PRIOR TO 338608, NEG 3 Boe 2 2 55 3 5 14 aw F > resistor 0 ra . Ss 22) 7 i i ae a 2” 2 & y a tf dial || ee MGLLS 6 1 L IL! j 1 ‘ | °. hs ame ae : aS re a ey f_1@) OF " # ne 20 S)) mm [OP soy ee 11415 Figure 4-19, Contactor Panel INDEX ART No. iwoex PART no. NO. NO. PARTNAME atao. NO. NO. PARTNAME REGO. saaree-or Cane Assy : BS 07723 Washer, Loc. Slt No.5 3 2 Soarae-o2 Cable Asy : 3 O61 Nut Hox B40 3 3 Stara! Gonmecor Assy : Br Gases? 24V Coniacter, Changeover 2 4% S04728-00 Cable Asoy : Zot 0565 Conc 26 2 5 Souree-od Cable Assy : 35! Staatt Red, Wrewound : & Sourae-ce Gable Assy : 50 Soerts Panel Wolsment 1 5 Soerens Cable assy : Si Grouae Serow, Bota, Brass, 14-2098 2 8 fetter Buse Bar 3 3 Grreno Washor Lock Spit 4 2 S Souree-o7 Cable Assy : 3 Grigre Seow, Tras 10-333 172 i 10 Getrieot Sime bey Ast, 1 Sec. : 3 G7ra0s Washer Spit No. 10 1 1 Gesret”” Gam, Sige : 3 Gonete Not ne tose : 12 Sosore Fuse. 120 Ae i 3 Goan : 13 voeas Screw ROT, Brass, 14.2062 2 a ores i 1 077209 Washer Lock Spit 1/4 2 3 Srro0r : 1 Grrios FlatBronae Washer i So guotry Sew Ad Ha 54098 i 1S Grosts Standafineito 2 3 Opes Seton Ad He 69276 a 13 Goast0 i S| Grroor Washar 802516 ts 1a Goagoe 1 <2 orrane Washer Slt, Lock, No.6 e 19 bsesoe 1 Stowe Hon make & 20 soerae : Geers Wo hamess Clamps, lack Nyon § 2 Soares. ; SS tasias amass Assy : 2 — Soaroecb Cable Ay : 3 Oosear "Pine (Part a tom 45 to Boosie Seow, As 40x58 3 SF Oossss—Conacto Plata of tom 45) 4 24 77007 Washer 502516 é + Contact Kit 900531-02, Complete set of contact tips for all contactors. PTW.40 427B. Contactor Panel Assembly. (Figure 4-19) ‘SEE SUPPLEMENT 187 AND 232 FOR TRANSISTOR CONTROL TRUCKS Contactor Panel Removal. a. Unplug battery quick disconnect. CAUTION: When disconnecting components, label or mark wires for ease of reinstallation. bb. Disconnect the quick disconnect positive cable at the fuse . Disconnect the positive cable at the reverse contac- tor. 4d. Disconnect the A-1 cable at the upper resistor ter- minal. €. Disconnect the two negative cables at the middle resistor terminal f. Disconnect the A-2, F-1 and F-2 cables at the forward/reverse contactors. ‘g. Disconnect connector. h. Remove the two nuts holding the contactor panel to the frame and slide the unit out ofthe truck. 2. Single Pole Contactor Disassembly. (Figure 4-20) a. Remove spring stud (7) and spring (6) b. Remove nut holding armature plate retainer (5) and remove retainer by squeezing in on tabs and lifting up. ‘¢. Slide braid assembly (3) off contact (8) and remove contact (8) and armature plat (9) and spring (6) 4. Remove nut and flat washer holding front con- tact (12) and remove contact. NOTE: If only contacts are to be replaced, no fur- ther disassembly is required. Proceed to step S and replace coil fe. Remove spacer (13). f. Squeeze sides of front molding (15) and pull for- ward to disengage from base molding (1). Remove base molding and remove front molding from frame (14). 428 8 Coil can now be removed from frame (14) by removing 3/4 inch long hex head screw and flat washer. }. Single Pole Contactor Reassembly. (Figure 4-20) ‘Place 1-1/4 inch long hex head bolt through bottom of front molding (15) and slide molding onto frame. ‘Attach coil (11) to frame (14) with flat washer and 5/8 inch long hex head bolt. Be sure braid as- sembly (3) has been attached to frame (14) with 3/4 inch bolt. cc. Attach frame (14) to base molding (1) by engaging slots at bottom of frame behind flanges near lower ‘edge of base molding. 4. Snap slots at top of front molding (15) into flanges ‘of base (1). Coil assembly should now be securely attached to base. . Install spacer (13) in front molding (15) and install front contact (12). Secure with washer, lock washer and hex nut. f. Place contactor on work surface with base molding, down. Place spring (6) on center of pole piece (10). 8. Position armature plate (9) against frame (14). bh, Place moving contact assembly (8) on armature plate, then attach braid assembly (3) to contact stud, i. Place retainer (5) over contact stud and slip the two tabs on retainer (5) into the two slots in armature plate (9). Secure with hex nut. |i Secure moving contact (8) to armature (9) with spring (6) and spring stu (7). |. Double Pole Contactor Disassembly. (Figure 4-21) a, Remove spring stud (7) and spring (6). b. Remove nut, bolt and washers securing buss bar to back contact (16). cc. Slide back contact (16) up as far as possible then ‘squeeze sides of rear molding (17) together and lift Off frame (14). Separate two sides of rear molding. and remove back contact. 4, Remove nut holding armature plate retainer (5) and remove retainer by squeezing in on tabs and lifting up, PTW-40PART NO. 005659 24V ASSEMBLY Figure 4-20, Single Pole Contactor Unit INDEX PART No. INDEX PART No, NO. NO. PART NAME REQD. NO. NO. PART NAME REOD. 1 905010 Base Moiging 1 9 905019 Armature Plate 4 2. 401181 Buss Bar 1 10 905020 Pole Peco 1 3t 905013 Braid Assy 1 11 905028 Coll Assy, 24 Vot 1 St 905015 Armature Pate Retainer 1 324 905022 Front Contact 1 & 905016 Compression Spring 2 13" 905023 Spacer 1 7 905017 Spring, Stud 1 34 905024 Magnet Frame 1 8+ 905028 Moving Contact Assy 1 48 905025 Front Molding with Blowout 1 + Contactor Repair kit, services one 2nd speed or one 3rd speed contactor - Order 900531-08. PTW-40 4-29€. Slide braid assembly (3) off contact (8) and remove contact (8), armature plate (9) and spring (6). £. Remove nut holding front contact (12) and remove contact. NOTE: If only contacts are to be replaced, no fur- ther disassembly is required, fg. Remove spacer (13). hh, Squeeze sides of front molding (15) and pull for ‘ward to disengage from base molding (1). Remove base molding and remove front molding from frame (14). i, Coil can now be removed from frame (14) by removing 3/4 inch long hex head screw and flat washer. 5. Double Pole Contactor Reassembly. (Figure 4-21) a. Place 1-1/4 inch long hex head bolt through bottom of front molding (15) and slide molding onto frame (14). b. Attach coil (11) to frame (14) with flat washer and 5/8 inch long hex head bolt. Be sure braid as- sembly (3) has been attached to frame (14) with 3/4 inch bolt c. Attach frame (14) to base molding (1) by engaging slots at bottom of frame behind flanges near lower edge of base molding. 4. Snap slots at top of front molding (15) into flanges of base (1). Coil assembly should now be securely attached to base. 4-30 Install spacer (13) in front molding (15) and instal front contact (12). Secure with washer, lock washer and hex nut Place contactor on work surface with base molding down, Place spring (6) on center of pole piece (10) Position armature plate (9) against frame (14), Place moving contact assembly (8) on armature plate, then attach braid assembly (3) to contact stud, Place retainer (5) on contact stud and slip the two tabs on the retainer into the two slots in the arma- ture plate (9), Secure with hex nut. Place two parts of back molding (17) together and slide back contact (16) into slot in molding. . Squeeze back molding together and place grooves in back of molding on the frame (14). Push mold- ing down to snap into position. Release back molding and press back contact (16) down into position. Armature will need to be pressed down to position back contact. Reattach buss bar (2) to back comact (16) using hhex nut and washers. Secure moving contact (8) 10 armature (9) with spring (6) and spring stud (7). PTW-40PART NO. 005657 24V ASSEMBLY 2 Figure 4-21. Double Pole Contactor Unit INDEX PART No. INDEX PART NO. NO. NO. PART NAME REQD. NO. NO. PART NAME REQD. 1 905010 Base Molding 1 10° 905020 Pola Fioce 1 2 407161 Buss Bar 2 11 905028 Coil Assembly, 24 Volt 4 3} 905013 Brad Assembly 1 12+ 905022 Front Contact 1 5 905015 Armature Pate Retainer 1 13° 905023 Spacer 1 8 805018 Compression Spring 2 14 905024 Magnet Frame 4 7 905017 Spring Stud 1 15 905025 Front Molding with Blowout 1 8t 905018 Floating Contact Assembly 1 36+ 905028 Back Contact 1 8' 905019 Armature Pate 1 17) 905027 Rear Molding 1 + Contactor Repair kit, services one forward or one reverse contactor - Order 900531-09. PTW-40 431C. Battery Charger. ‘on the upper left hand panel. (Figure 4-22.) All replace- ‘The battery charger is mounted in the lower right of the @bI€ parts are shown in Figure 4-23 truck, while the plug-in connector and meters are mounted Figure 4.22, Battery Charger Mounting INDEX PART No. INDEX PART No. NO. NO. PART NAME REQD. NO. NO. PART NAME REQD. 1 056111 4*Cable Tre 7 14 029036 Wire, 10 Ga. Standard TF 2 005655.01 Cable Well Bushing 2 15 059421 Hox Nut, 62 4 3 402064 Spacer 1 36 077209 Washer, Lock, Split 1/4 4 4% 005401 Grey Anderson Connector 2 17077031 Washer 4 5 021237 Terminal Bing 4 184 402475 Cover, LH, w/ Chargor 1 8 059412 Hox Nut 114-20 2 59 901030 Fuse, 15A, 60 Cyclo 3 7 077208 Washer, Lock, Spi, No.6 2 900847 Fuse, 10A, 50 Cyclo + 8 005454 Connecior Inlet Flange. 1 20 901021 Fuse Holder 1 8 068231 892x1/2RdMachine Screw 2 21 900876 Knob, Timer 1 10 900373 Indicator Light 5 22 900897 Screw, 8:92 x 1/8 3 41 900462 Ammeter 1 23 900475 Plato, Dial, Timor 3 12 900375 Charger, Timer 60 Cyclo 1 24 005810 Cord, Charger, 120V, 10F1. (Opt) t 900749 Charger. Timer 50 Cycle 1 508589 Cord, Charger, 240V, 10F. (Opt) + 023137 Hamess Assy, Chargor + Trucks with other options, e.i. hourmeter ~ see Figure 5-2. 432 PTw-40REPLACES INDEX PART NO. NO. 004957-01, (008957-02 01023 so1026 900564 00466 ‘900465 ‘900507 (068408 (077505 050416 PTW-40 NUMBERS 329224 and HIGHER: ITEM #18 FOR SERIAL Figure 4.23, Battery Charger No. PART NAME REQD. (Charger, 120V-10-60 He, 154, Charger, 240V-1050 Ha. 154 Translormor, 120V-10-60 Hz Translormer, 240V-10-50 He ‘Screw, Sell-Tapping, 10-32 x 9/8 Strap Capacitor Namopiaie Scrow, No. 4x16 Screw, 10-32% 172 pede 0 Nut, Hex, 10:32 INDEX NO. 10 " 2 3 “4 5 6 v 18° io es PART NO. ‘901026 901028 ‘01031 901029 ‘901027 be 4 t o77207 ‘901022 ‘900d64 ‘901203 * Serial No. 329223 and lower * Serial No. 329224 and higher + P/O Heat Sink and Rectifier Assy. PART NAME Insulator ‘Terminal Board, 60 Cycle ‘Terminal Board, 50 Cyoe Nut, Hex, 10-92, Small oat Sing & Fectir Assy. Rector Ineulator ‘Spacer-Insulator, Nylon ‘Washer, Lock Spit, 10 ‘Creut Breaker Fuse Fuse Holder Assy.1. SEE SUPPLEMENT 232 FOR TRANSISTOR 2. SEE SUPPLEMENT 187 FOR TRANSISTOR SPEED CONTROL TRUCKS SERIAL NUMBER ‘SPEED CONTROL TRUCKS SERIAL NUMBER 338608 AND HIGHER PRIOR TO 338608 e Se hene-p oo Figure 4-24. Wiring Diagram PTW-40 Truck 4-34 PTW40g098EE OL HOId HIEWNN ‘WIH3S SHONUL TOHLNOD G33dS HOLSISNVHL ¥Od 281 INAWAIddNS 33S TLS NOH 6 SHIH aaron GNY sossee HASWNN “WIHAS SHONUL IOULNOD (G33dS HOLSISNVYL YOd Zez LNAW3IddNS 33S “b le =o oe | Yaa ol = SEY a Shon | Le = Le! Bes ¥ 4-35 Figure 4.25. Electrical Schematic4-6. HYDRAULICS. ‘A. Line and Fitting Replacement. WARNING: Lift carriage must be fully lowered before performing maintenance on the hydraulic system, NOTE: Leaking hydraulic fitings may be remedied by simply tightening fitting. If this does not remedy the leak, the fiting or line must be replaced. 1. Lower lift carriage fully. 2. Remove leaking line or fitting and replace it with a ‘new line or fitting, INDEX PART No. NO. NO. PART NAME REQD. Tf 047570 Cylindor Assombly (Seo Figure 4-92) 1 2! 025525 Elbow, 8 10 1 3 0255@5 iting 4 4 402481 Pin 1 5 069603 Scrow, 98-18 x94 4 6 —O77211 Lock Washer, 78 4 7 04710 Mount Weldment 4 8 069478 Screw, 11420 x 6 2 9 402460 Hydraulic Cover 5 40 064605 Scrow, 38-18 x1 1 11 O77211 Lock Washer, 98 1 12 50473201 Hose Assy 1 13059618 Nut, Hox, 10-32 2 14077208 Lock Washer 2 CAUTION: Hydraulic oil can dissolve the batery case Wipe off any oil immediately 3. Remove the breather cap (19, Figure 4-26), and replace any hydraulic fluid that was lost during line replace- ‘ment, NOTE: Refill only with Big Joe Hydraulic Oil, Part No. 900855. 4, Reinstall the breather cap and operate the lift-lower, to refill the cylinders and lines with fluid. 5. Lower the lift carriage fully, remove the breather cap and again check the reservoir fluid level, INDEX PART No. NO. NO. PARTNAME REGO. 35\ 077090 Washer 2 36 262500 Tubing, 1/4 3.00 37028125 Elbow, 7/16 o tubo 4 18 028535 Elbow, 9/16 0 JIC 38076701 Breather 20 (SeeFig. Pump and Motor Assy + For repair parts on old cylinder assembly, 504712, see Figure 4-31. #27) 2105579 Oll, Hydraulic. aR 2 023134 Wire Hamess 1 23 61716 Snap Ring, 5 2 24 057515 Grommot i 25 069712 Screw, Fat Hd, 98-18 x4 2 2 0s6i11 Tie 6 27 009602 Hom, 24v 4 PTW-40Figure 4-27. Pump-Motor-Reservoir Assembly INDEX PART NO. NO. PART NAME “016910 Pump-Motor-Reservoir Unt 016591 Pump:Motor-Reservor Unit 016593 Pump-Motor-Reservor Unit 900991 Pump Motor (See Figure 428) 905045 Pump Motor (See Figure 429) 906165 Pump Noor (See Figure 430) 020715 Solenoid, Motor 056353 Coupling 900682 elie! Valve Kit No. REQD. 1 INDEX NO. 5 6 v 8 9 10 2 PART NO. ‘900695 ‘900688 (048133 ‘900664 ‘900894 ‘200699 026703 ‘900270 PART NAME ‘Check Valve Assembly Flow Regulator Kit Solonoig Release Valve, 24 Volt ‘Adapier-Pump Reservor Kit O-Ring Reservoir ibow, Stes! Strainer * Used on trucks prior to S/N 318250. For complete unit replacement use P/N 016593. “Used on trucks S/N 318250 thru 325168, and 332121 thru 335304. For complete unit replacement use P/N 016593. + Used on trucks SiN 325169 thru 332120, and 335305 and Higher. PTW-40 No. REOD. 437B. Hydraulic Pump-Motor-Reservoir Assembly. (Figure 4-27) ‘The hydraulic pump-motor-teservoir assembly may be repaired. The motor can be rebuilt, but a defective pump hhas to be replaced as a complete unit. Refer to Figures 4-28, 4-29, and 4-30 for breakdown of motor. Proceed as follows to remove and disassemble hydraulic pump-motor reservoir assembly: |. Lower backrest/fork fully and disconnect battery. WARNING: Before disconnecting hydraulic lines, make certain that the system is not under pressure. 2. Remove cover for access to pump assembly. PART NO. 900991 USED ON TRUCKS PRIOR TO SIN 318250 3. Remove hydraulic lines from pump and electric wires from motor, labeling each wire to assure proper reas- sembly. 4, Remove assembly from truck by removing the screws and lock washers that secure it to the frame. 5. Unscrew breather cap and drain the hydraulic oil from the reservoir into a clean bucket or suitable container. 6. Disassemble using Figures 427 and 4.28, 4.29, 4-30 asa guide. NOTE: Before reassembling pump-motor-reservoir assembly, it is recommended that all (Orrings and gaskets be replaced. Figure 4-28. Pump Motor Assembly for Trucks Prior to S/N 318250 INDEX PART No. NO. NO. PARTNAME REGO. 900961 Pump Motor Assy (MFO-7009) 1 900495 ‘Drv End Bearing 1 2 01501 Armature 1 3 900984 Terminal Std Package 1 4 900983 Field Goll Package i 5 900172 Thrust Washer Package 1 4-38 INDEX PART No. NO. NO. PARTNAME REQD. ‘6 900875 Commutator End He 1 7 so0e2 Brush Sat 1 8 900889 Plate Assy Brush 1 9 900432 Thru Ball Package 1 10 900883 Spring Set, Brush 1 11 900996 Spacer Package, Drive kind 1PART NO. 905046 USE ON TRUCKS SiN ‘918250 THRU 325168, 332121 THRU 335304 Figure 4-29. INDEX PART NO. NO. PART NAME 905046 Pump Motor Assembly 1 905047 "Fred Col'24 VOC 2 905048 Armature 3 905049 Bearing 4 Notused 5 905051 ‘Flat Head Screw & 905082 Retainer 7 905084 Bearing 8 905030 Spring Washer 9 905031 Retainer 10905032 Terminal Stud Pig, PTW-40 No. REQ. 1 1 INDEX NO. " 12 13 “ 15 16 ? 18 19 2 at PART NO. 905033 905034 905037 905038 905038 905040 05041 05082 905043 905086 905085 Pump Motor Assembly, on Trucks S/N 318250 thru 325168, and 332121 thru 335304 PART NAME Protective Cap Commutator End Shield fil Screw Fillster Head Screw ‘Spring Lock Washer Filiste Head Serow Brush Holder ‘Spal Spring Carbon-Brush Set Fin aon enews BBPART NO. 904165 USED ON TRUCKS SIN 325169 THRU 332120 AND 335305 & HIGHER invex NO. Figure 4-30, Pump Motor Assembly, on Trucks S/N 325169 thru 332120, and 33830 and Higher pant NO. goates Not uses ‘900495 904172 ‘904166 904175 ‘904174 PART NAME Pump Motor Assembly Sealed Ball Bearing Spacer, Armature, DE mature Soring Washer Thru Bolt & Insulation Package No. REQD. t iNpex NO. 7 8 8 10 " 2 3 PART NO. 04170 oat7t oos7i4 s0a167 904169 908173 PART NAME Head, Commutator End ‘Brush Plate Assembly ‘Brush Spring Set Brush Plato. rush Set Fiald Coll Package Terminal Stud Package No. EOD. PTW-40PART NO. 504712 INDEX PART NO. _NO. 61824 49510 aozaaa anzeas 042136, s024a6 PTW-40 Figure 4-31. Lift Cylinder, P/N 504712 PART NAME Internal Snap Ring ier, Rod. Polysttnane Head, Cylinder od, Gyinder O-Ring Piston No. REGO. USE FOR PARTS INFORMATION ONLY FOR COMPLETE CYLINDER REPLACEMENT USE CYLINDER P/N 047570 (Figure 4-32) PISTON ROD 12 CruiNDeR USED ON TRUCKS PRIOR TO SIN 331987 INDEX PART No. NO. NO. PART NAME EOD. 7. o77121 Washer 1 8° 043108 Packing Set 1 8 077008 Washer 1 10059128 Nut 1 11 508711 Cylinder, Weldment 1 42° 900931 Cylinder. Too! 1 s these items. 441C, Lift Cylinder Removal. (Figure 4-26) |. Lower the forks completely and disconnect the bat teries. 2. Remove cover (9, Figure 426). Disconnect the hydraulic hoses (12) and (16) at the pump and drain fluid in the lines into a clean container. 3. Disconnect hydraulic hose (12) at the cylinder elbow (2). 4, Remove the snap rings (23) from the pin (4) and slide the pin from the yoke. 5. Remove the screw (10) and lock washer (11), attaching the cylinder rod to the backrest. 6. Tilt the bottom of the cylinder out, and lower cylinder assembly down for access to the upper hydraulic fit- ting. 7. Disconnect hydraulic line (16) from the fitting 3), and complete removal of cylinder assembly. D. Lift Cylinder Identification. Two lift cylinders have been used on the PTW series trucks. For proper parts replacement and repair instruc- tions, this identification is important. The eylinders can be differentiated by looking at the overflow port near the top of the cylinder. The port on older cylinder P/N 504712, is smooth to the surface of the cylinder, while the port on new cylinder P/N 047570, is on a protruding boss as shown in figure 4-32. E. Lift Cylinder Repair - P/N 504712 (Figure 4-31). To rebuild or replace components in the lift cylinder, proceed as follows: IL Secure the lift cylinder in a vise, clamping on the bot- tom connecting yoke. 2. Remove the intemal snap ring (1, Figure 4-31) from the cylinder tube weldment (11). 3. Withdraw the cylinder rod (4), wiper rod assembly (2 and 3), and internal components (6 through 10) from the cylinder. CAUTION: Use proper pipe clamp vise with non- marring jaws to prevent damaging the finish ofthe rod 4, Secure the cylinder rod with attached pars in a vice ‘with non-marring jaws and remove (10,9, 8, 7 and 6). 5. Replace all glands, seals and damaged or wor pats. CAUTION: Reassembly of the lift cylinder requires use of a special tool, Part No. 900931, to prevent damage to cylinder packing 6. Insert special tool, No. 900931, into the end of the lift cylinder as shown in Figure 4-31 inset. 7. Coat rings and seals with petroleum jelly and inser cylinder rod assembly into cylinder. 8. Remove special tool and slide the wiper rod assembly down over the rod and into the cylinder. Secure with the intemal snap ring (1). F. Lift Cylinder Repair - P/N 047570. (Figure 4-32) 1. Using cleaning solvent and clean rags, clean outside of lift cylinder. 2. Secure lift cylinder in a vise and extend the chrome od (7) fully NOTE: Do not overtighten vise. Make sure that both lift cylinder ports have all. restrictions removed. 3. Remove retaining ring (12) and slide piston-chrome rod assembly (7) and intemal components (8 through 11) out of barrel (1). CAUTION: Use proper pipe-clamp vise with non- ‘marring jaws to prevent damage to finish on chrome tod, 44, Secure piston-chrome rod assembly (7) in a soft jawed 5. Remove nut (2), piston (5), and O-ring (6) from chrome rod (7). 6. Remove O-ring (3) and backup (4) from piston (5). 7. Using cleaning solvent and clean rags, wash and dry barrel (1), chrome rod (7), head (9), piston (5), and snap ring (12). NOTE: Before reassembling the lift eylinder, make sure that there are no damaged parts. Use new O-rings and dust seal from packing kit PIN 901206 when reassembling the lift cylinder. 8. Apply petroleum jelly to O-rings and seals (3, 4, 6, 8 10, and 11) during assembly, taking care not to score ‘O-ring (6) on chrome rod (7) threads. 9. Place O-ring (3) and backup (4) on piston (5). 10. Secure chrome rod (7) in softjawed vice and reas- semble O-ring (6), piston (5), and nut 2) on chrome rod. 11. Slide piston-chrome rod assembly (7) into barrel (1) ‘and replace internal components (8 through 11). 12, Secure with snap ring (12). PTW-40G. Lift Cylinder installation. Lift cylinder installation is essentially the reverse of in- structions for removal, refer to paragraph 4-6C. New Cylinder Old Cylinder Part No. 047570 Part No. 504712 OVERFLOW PORT USED ON TRUCKS SIN 331987 AND HIGHER Figure 4-32, Lift Cylinder, P/N 047570 INDEX PART No. INDEX PART No. NO. NO. PART NAME. REQD. NO. NO. PART NAME REQD. 1 901212 Bare! 1 7, got2t1 Chrome Rod 1 2, 901207 Nut 1 as Osrng 1 3° Oring 1 8 Head 1 o Backup Ring 1 10: xing 1 5 Piston 1 " Dust Seal 1 6 O-rng 1 42 901210 Snap Fing 4 * Included in Packing Kit 901206 PTW-40 4.43SECTION V OPTIONS 5-1. KEYSWITCH. (OPTIONAL) ‘The optional Keyswitch is shown in Figure 5-1. The ‘modification of the wiring harness that is required for keys- ‘witch installation is shown in Figure 5-1 and in the wiring diagram in Figure 4-24 Parts List for Figure 5-1: INDEX PART No. NO. NO. PART NAME REQD. 1023129 Wing Hamoss 1 2 021203 Terminal 2 3 020725 Switch, Key 1 5-2. HOUR METER. (OPTIONAL) ‘The hour meter is available for attachment to the motor cir- cuits to indicate use of the drive and lift functions. Refer to Figure 5-2 for replacement parts and wiring information. ‘The addition of an hour meter or hour meter in combina- tion with a battery discharge indicator will require a new instrument panel as detailed in Figure 5. rem @ 4 aa oe itamrn wo enon) 3 ‘om era wowan) 4 (om wera wor a ewan) Figure 5. INDEX PART No. NO. NO. PART NAME REQD. 1 402477 anol (HR MTR WO CHGR) 1 2 402676 | (HF MTR WY DI IND) 1 3 402473 1 4 402465 Panel (HRMTRW/DL&.CHGR) 1 5 077203 Washo, Lock, Spt, No.5 3 & 050410 Nut, Hex, 5-40 3 7 021207 Terminal, Ring, 5/18, 1 8 021203 Connector 1 9 068179 Screw, Rd Hd, 5-40 x58 3 PTW-40 ‘CUT #3 WIRE AT THIS POINT, ATTACH TERMINALS TO RESULTING ENDS. Figure 5-1. Keyswitch re. a . Hour Meter Installation INDEX PART No. NO. NO. PART NAME REQD. 30" 015608 Hour Meter 1 11 005903 Diode Assy 3 42 010810 Pad, Insulating Diode 1 13 023018 Wire, Black, No. 16 aR 14 005849 Connector 2 45 056111 Cable Tis, 4" Long 3 36 005847 Connector } 47 021718 Terminal, Sip On 4 18 005825 Contacts, Male a 545-3. BATTERY DISCHARGE _—INDICATOR. (OPTIONAL) Replacement parts and required instrument panels for the optional Battery Discharge Indicator are detailed in Fig- ute 5-3 rem a] (ox =s/oue) 5 a 1G fee ees — 6 7 8 e ° (ee ofc e .oue) wo rome nero ee Figure $-3. Battery Discharge Indicator Installation INDEX PART No. INDEX. PART No. NO. NO. PART NAME EOD. NO. 'NO. PART NAME REGO. \° anatie Panel (DI WO CHGR) 7 © 021718 Terminal, Sip On 2 2 aea76 Panel (DIWIR MTA) 4 7 gore Wick 16 aR 3 fez 3 3 beers Can 2 4 Maaaes 3 $ Getzor Forma Bing, 16" 2 5 010819102 Meter, 24V Bakery Cap : 52 PTw-405-4. COLD CONDITIONING PACKAGE. (OPTIONAL) Operation of the PTW-40) truck under continual below freezing temperatures in applications such as meat lockers PaRT No. 35 NO. PART NAME REQD. 1 055753 Grease aR 2 020680 Swifch, Deadman 1 3 019910 Fleet Sain 1 023135 Cable Assy. Deadman REF 5 056491 Decal, Cold Conditioning 1 & 055790 Oi, 101% aR 7 055768 —Hydrajak Ol Permatex 72 aR 8 052816 Bracket 1 9 068177 Screw, RAHd. 5-40.x3/8 2 10059632 Nut Hex. Lock $40 THD 4 11088179 Seraw, Rd Hd, 5-40 «5/8 2 PTW-40 and freezers, requires the changing of oils and greases and ‘modification of the control head and deadman switch as detailed in Figure 5-4 oF 5-5, and Wiring Diagram 4-24. USED ON TRUCKS PRIOR TO S/N 332483 igure 5-4. Cold Conditioning Package, Prior to SIN 332483 INDEX PART No. NO. NO. PART NAME RED. 12) 400544 Bracket, MTG Res 1 13 023014 Wire, 18 Ga, Red PVC. NR 44 005643 Terminal, Contact Pin 1 18 005649 Connector, Splice 1 46 021204 Terminal, Side Cp, 1/4 2 17005422 Connecter, Inline Insulated 1 18 020735 Seiten, Thermal 1 18 400044 Bracket, Thermal Cutout 1 20 018202 Switch, insulator 1 21 01800910 0nm, 20 Watt, Heat Resistor 2 5:3USED ON TRUCKS SIN 332483 & HIGHER Figure §-5. Cold Conditioning Package, S/N 332483 & Higher INoEX PART wo. INDEX PART wo, NO TNO. PART NaMe eas, wo, "no. reas, ogoedo Semen Deainan ‘ 1S case an 2 Oigo10 Rose Sram 1 1s Greete : & estas Cabo Aas Desdiman her 13 Oraaopon 2 {OSeust Seen Cou Conanoring : te orraoe 2 Sones Sew 2 1 Grrr 2 & tsoese Nut tock 3 13 sczees : 5 arse Swish tema! ; 1s caer ha & foooet Brace 1 Css7s0-" Grosse an $Gieeea Teal Conact on : 2055770. yale Ot as 10 fonses racket Restor : tssree Pyare Ot ra 1 dtao0a Toor, 2oWat HesiResstoe 2 21 Oserao-, Hanamiszon Ol in 12 00863 Comet, Spee ; Ossro0~ ‘Traamssen Ol a * For intermittent operation below 32" F. e “* For continuous operation below 32° F. 54 PTW-405-5. STABILIZER. (OPTIONAL) 5-7. CASTERS. (OPTIONAL) Stabilizer bars are available for installation on trucks that are used on rough or potholed surfaces. See Figure 5-6 for parts required. Figure 5-6, Stabi INpex PART No. NO. NO. PART NAME REQD. 1 402461 Stabilzer Bar 2 2 064805 Screw. Hox Cap 98-16 x1 4 3077211 Lock Washer, Spit 98 4 5-6. BACKREST. (OPTIONAL) A load backrest (Figure $-7) is available for addition to the PTW.-40 to allow handiing of high loads. Figure 5-8. Casters INDEX PART No. NO. "NO. PART NAME EOD. '508620-01 Caster Assombly 2 1 402288 1 2 402282 1 2 402280 2 4 0sta08 16 5 oss7ts 1 6 504621 Arm Weldment 4 7 083083-01 Bushing 2 8 402290 Shaft 1 9 061004 in, Roll 1 10 075078 Spring 2 11 402201 Arla 4 12051154 Bearing, Thrust 2 13 078263 © Wheel 1 1% 081152, Boating 2 35059685 Nut, Lock 1 46 025713. —“Fiting Grease 1 17 402327 Clamp. 1 18 025702 ‘Fiting, Groase, 65° 1 19 069553 Scrow, 116-18 x38 2 Figure 5-7. Backrest 20 © 077210 Washer, Lock 5/16 2 21059706 Screw, Pan Hd 8 INDEX PART No. NOTE: To add casters to 9 truck not originally equipped NO. NO. PART NAME REQD. with casters, order Retrofit Kit PIN 903440, installa- 1 804739-01 Backrest Installation 1 ton instructions are included In kit. PTw-40 55SECTION VI TROUBLESHOOTING e@ 6-1, TROUBLESHOOTING CHART MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION ‘Truck will not run, a. 120 AMP fuse blown. ‘8. Check fuse and replace if lift system does not operate. necessary. ». Battery dead or disconnected, ¢. Keyswitch defective. 4, Defective wiring. ’. Check battery and quick disconnect. . Bypass keyswitch to determine if it is malfunctioning. d. Check for open circuit and repair as required, ‘Truck does not run forward or reverse. All other functions ‘operate normally. ‘Truck runs forward but notin reverse. ‘Truck runs in reverse but notin forward. Check all wiring. A loose connection may be the cause ‘of malfunction. b. 15-amp control ci fuse blown. . Defective deadman brake switch 4. Forward or Reverse s\ ‘control head broken. uit itch Defective switch in control head or defective contactor. Defective speed control switch or defective contactor. ‘a. Tighten all loose connections before further troubleshooting. '. Check fuse and replace if defective. . Check and replace switch if defective. 4. Check and replace switch if defective. (Check for positive de voltage at number [wire on reverse contactor. If not present when steering arm is in operating position and speed control isin reverse, speed con- trol switch is defective. If voltage is present, contactor is defective. (Check for positive de voltage at number 2.wire on forward contactor. If not present when steering arm is in operating position and speed control switch is in forward, speed control switch is defective. If volt- age is present, contactor is defective. ‘Truck runs forward and in reverse at slow speed; will not run higher speeds. ‘Truck runs forward and in reverse at second or third speed only. Truck does not move when control isin first speed position. Everything else is normal. 1. Defective second and/or third speed contactors. b. Defective 3rd speed c/o switch. €. Defective time delay. Defective or open speed control resistor. ‘a. Check coils for continuity. Replace as, required. ». Replace. ¢. Replace. ‘Check for clean, tight connection. Check resistor for continuity and replace as required. Mechanical brake grabs Brake linkage overadjusted. ‘Adjust brake. When steering arm is in ‘operating position. Oils sprays or flows from top Defective packing in lift cylinder. (Overhaul lift cylinder and ‘of the lift cylinder. PTW-40 packing, seal, and wiper ring. et‘MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION ‘Sqealing sounds when lifting forks a. Oil level 100 low. 1, Add oil to reservoir. b. Dry channels in frame. b. Apply grease. Fork section does not lift to top. ‘Weak, slow of uneven action of hydraulic system. ¢. Defective carriage bearing. Oil level 100 low. ‘a Defective pump or relief valve , Wom lift cylinder packing. c. Load larger than capacity. ¢. Replace bearing. ‘Add oil to reservoir. ‘a. Cheek pressure. Adjust valve. ». Repack cylinder. ¢. Refer to name plate on power frame for for maximum load capacity. 4, Defective lift motor solenoid. 4. Replace. €. Battery charge low. €. Charge battery, Forks do not lift, motor does ‘a Battery is dead or disconnected. a. Check and recharge if required. ‘ot run. », Defective wiring. 'b. Check and repair as required. c. Defect in electrical system for ‘operating pump motor. . Check lift switch in control head as well the solenoid on the motor. Repair or Forks do not lift, motor runs. Defect in hydraulic system, Tevel inthe reservoir and to the lift cylinder, and repair b. If normal, check the hydraulic pump, and relief valve. Repair, of adjust. Forks lift, but will not go down. Defect in hydraulic system. ‘Check the lowering control switch as well as the lowering valve, and look for obstruc- tion in the hydraulic line. Repair or adjust as required. Toad will not hold. Forks creep downward under load when in a raised position, «a, Oil bypassing intemally between ‘check valve and adapter body. ’b. Wom lift cylinder packing. Leak in hydraulic system, cylinder packing, or lowering valve. ‘2 Disassemble, clean, and reassemble. Re- place wom pars as required. bb Replace cylinder packi Examine the lowering solenoid valve and internal check valve for obstructions pre- venting valve from closing cempletely to block oil. Look for leaking fittings in the hydraulic line. Check pump and suction line for leakage back into the reservoir. Repair or replace as required. Sieering arm does not return to the upright position. ‘a: Return spring improperly adjusted. b. Binding brake linkage or electrical cable. ‘a. Readjust spring tension. . Check and free the binding item, “Truck moves when arm is pulled down. ‘a Belly-button switch defective ». Short in control head. ‘8 Check for shor, and repair or replace as necessary. ». Check wiring and repair as required. ‘Steering arm jerks excessively starting or stopping the truck. ‘a, Worn steering arm pivot bushings. ». Drive wheel tire worn, ‘a Replace bushings. b. Replace drive wheel. Drive motor is jerky. Motor commutator wom. Replace motor. 62 PTW-406-2. CONTACTOR AND SWITCH TROUBLESHOOTING. ‘SEE SUPPLEMENT 232 FOR TRANSISTOR CONTROL TRUCKS If the truck does not run in one of the modes (Example: truck runs in all forward speeds, but notin reverse), the fol- Towing tests can be performed to determine whether the problem is in the switches or the contactor unit itself. ‘A. Contactor Testing. 1. Make certain battery is in good condition and fully charged before beginning tests. 2. Disconnect the battery and place strips of cardboard between the contactor tips to prevent current from flow- ing during the test. 3. Reconnect the battery. 4. Place the VOM test meter on the SOV scale and con- rect the test probes to the (+) and (-) coil connections Of the suspect contactor. (Figure 6-1). NOTE: Testing of the reverse contactor is shown in Figure 6-1. place the steering control in the run position (brake off) and depress the speed control PTW-40 6, Voltage should read 24V. If voltage does not read 24V, the problem is in the switches or wiring leading to the contactor unit. (See Paragraph B for switch testing.) If 24V is present, the problem is in the contactor uni and the contactor must be disassembed and the coil re- placed. B. Switch Testing. 1, Disconnect the battery, 2. Set the VOM test meter on the RXI scale. 3. Connect the meter test probes to the common #3 and the suspect switch lead® at the 15 terminal connector. “NOTE: #1 switch lead for the reverse switch is shown in Figure 6-2 4, If truck is equipped with a keyswitch, tum it on and lower the control handle to the driving position 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 for wiring Teading to the connector is defective and ‘must be repaired or replaced. 63PTW-40 Figure 6-2. Switch Testing 656-3. CHARGER TROUBLESHOOTING. ‘Check A.C. power supply (plug, cord, fuse wall circuit breaker, etc.) Check for physical damage (broken or loose) Check D.C. output. a. If fuse blows or circuit breaker trips, check for reverse polarity of batteries. b. Check for defective diodes. (See Step 6). Check parts (ammeter, timer, diodes, transformer, con- denser, fuses, etc.) for tight connections. Look for dis- colored connections and broken or loose wires. Check condition of batteries (check each cell) for: + Specific gravity (before and after charge). + Volts/cell (before and after charge). + D.C. current at start and finish, while on charge (charger on). + D.C. volts at stan and finish while on charge (charger on). "Quick Tips" for checking charger operation, a Open circuit: (without batteries plugged in) D.C. volts = rated volts X 1-1/2 range is normal. b. Short circuit: Anderson plug with a loop from posi- tive to negative to form the short circuit and plug into charger D.C. plug = 80% of normal D.C. amp ‘output on ammeter. . Shorted diode: check with ohmmeter, positive lead ‘0 D.C. negative, negative lead to D.C. positive; if normal, current will pass. Reverse test leads and current will not pass. If shorted, current will pass both ways. If one diode is open, charger amp out- put will be about one-half normal and may draw high A.C. amps, see data plate for normal amps, ‘This test can be made at end of D.C. plug. 4d. Check diodes: disconnect diode (unbolt base or cut flexible lead) before testing. Set ohmmeter to R X 100 range, with positive test lead (red) on an- rnode (stem) and negative lead (black) on base (Figure 6-3), current should pass (+ 10 -). Reverse test leads and current should not pass. © Check capacitor: (short outwith insulated screwdriver before test). Disconnect leads, set ‘ohmmeter to highest scale with leads to capacitor terminals. If needle deflects (midscale) and is fol- lowed by a deflection in the opposite direction, capacitor is good. If no deflection, capacitor is ‘open. IF the meter needle moves and stops, the capacitor is faulty. f. Check condenser winding: check A.C. volts, open ‘condenser circuit range (condenser out of circuit) 280 to 330 volts A.C. (plugged in) 400-435 volts A.C. range. Normal Battery, Voltage Table (while battery “on charge") Battery Size | Start Rate Finish Rate inD.C.Vot_| D.C. Volts | D.C. Volts 24 25.6 30.0 OHMMETER AT Rx100 Figure 6-3. Diode Test PTW-40