PDCB, PDH, PDM PPT-30 and PPT-40 BIG JOE MANUFACTURING COMPANY 7225 NORTH KOSTNER AVENUE Linconwood, ILLINOIS 60646 ADDENDUM COLD CONDITIONING Table 1. Cold Conditioning ‘Tauck ‘SERIAL BASIC CONTROL HEAD MODEL NUMBER BREAK MANUAL ‘SUPPLEMENT Poca 87702 Poca0278 Poceo778SUPP PDH 87695, POH1078 POM 87723, PoMo378 PDMOT7ESUPP PPT-30 e747? PPTOS7S PPTO7TESUPP Per-40 87982 PpTO2TS PPTO77ESUPP 1. GENERAL. ‘The cold-conditioning version of the truck differs from the standard model where necessary to improve performance in winter temperatures. Heating resistors are provided for the control head switches, and cold-resistant versions of other switches and the hydraulic hoses are used. Special cold- temperature lubricants are also necessary for this application. ‘Table | lists truck and corresponding seria! number breaks. Cold-conditioning equipped trucks with these and higher serial numbers are covered by this addendum. For earlier Suet trucks refer to applicable cold conditioning addenda. Location of electrical parts in the control head and resistor wiring of 12-and 24-volt cold-conditioning equipment is illu- strated in figure 1, Figure 2s an electrical schematic diagram of the thermal switch and resistor network. Figure § shows the PDH and PDM cold conditioned lift control valve; figures 6 through 10 identify and locate cold conditioning parts as in- stalled inthe control head and brake linkage. Figures 11 through 15 are wiring diagrams for cold conditioned trucks. DESCRIPTION a. Operation. Normal lift truck used is unaffected by installation of cold conditioning equipment. Operation of the cold conditioning equipment itself is automatic: the thermal cutout switch con- neets battery voltage to the heat-producing resistors when the ambient temperature falls below a preset level. A decal applied to the truck exterior near the battery disconnect point alerts truck users to cold conditioning equipment. C7 8 wines id we connconpToNNs Re ‘2 vour 28 Vout Figure 1. Location of Resistors and ‘Thermal Cutout Switch. GEN0479ADD Figure 2. Schematic of Resistors and Thermal Cutout Switch, AMCAUTION Cold conditioning heating resistors con- sume power when energized, whether truck is used or not. To avoid power waste, dis- connect battery of cold-conditioned truck when lengthy storage periods at tempera- tures low enough to energize cold condi- tioning equipment are planned. b. Lubrication. ‘The manufacturer has installed lubricants specially formulated for low temperature use in cold conditioned trucks. When adding grease or oil to the cold conditioned truck, the follow- ing lubricants are recommend PART NO TEM 055753, Grease 055784 Hycraulic Oi! ¢. Dead-man Switch. Dead-man switch part no. 020729 has been replaced by dead- ‘man switch part no. 020690 and strain-relief part no. 019910 (figures 3 and 4). Switch 020690 is sealed against low-tempera- ture damage. Refer to table 2 and revise the lift truck manual accordingly to reflect the addition ofthe strain relief and re- placement of the dead-man switch. Table 2. Dead-man Switch MANUAL FIG.NO., No. INDEX NO. poca0278 38,15 POH1078 314,34 PoMoa78 38,34 PPTOs76 36.8 PeTOz78 39,15 4. Lift Limit Switch. (On PDH and PDCB trucks, lift limit switch part no. 020703, and strain-relief part no. 052905 have been replaced by lift mit switch part no. 020689 and strain-relief part no, 019910. The ‘new parts are sealed against low-temperature damage. Revise the lift truck manual accordingly to reflect the replacement of ‘he lift limit switch and strain-relief (PDCBOZ8, figure 3-35 for PDCR trucks; PDHI078, figures 3-45 and 3-46 for PDH. trucks). AQ e. Lift Control Valve. (On PDH and PDM trucks, lift control valve assemblies have been cold conditioned by installing switch part no, $03210 and strain relief part no. 019910 in place of switch part no, 00942. The new parts are sealed against low temperature damage, Figure 5 illustrates the lift control valves and associated parts on cold conditioned PDH and PDM trucks. BRACKET STRAW REGIE ine >" DeASMAN ‘Swiree (020800. Figure 3. Deadman Switch and Strain Relief PPT-30 Trucks sian © | Reree Bastin =) ‘019910 Benowan ae “00600 Figure 4. Deadman Switch and Strain Relief PDCB, PDM, PDH, and PPT-40 Trucks f. Maintenance. Cold conditioning equipment requires no regular maintenance and does not affect any lift truck maintenance procedure ex- cept lubrication where the low temperative lubricants must beused. Instructions for disassembly of control head assem- blies to gain access to cold conditioning resistors and thermal ccutout switch can be found in the repair section of the basic ‘manual and/or control head supplement (see table I) GENO479ADDINDEX PART ‘NO. GENO479ADD NO. 240501 oa2t04 504611 400085, 70475 05795) (055701 (060937 059529 2s7401 o7s015 (060608 ast404 075082 063478, Figure 5, Lift Control Valve - Cold Conditioned, PDH and PDM No. PART NAME. REOD. Valve Body O-Ring Release Cam Switch Bracket Philips Round Ha Screw, 1/4-20 x 3/8 Knob Lever Roll Pin Jam Nat, 3/8-16 Valve Clamp Handle Return Spring Valve Pin, §/32 1-1/4 Check Ball, 3/8 Compression Spring Hox Ha Cap Screw, 1/4-20 x 3/4 INDEX. PART No. NO. 16 077209 17026303 18026109 18026500 19503210 20 Not Used 21039432 22 400051 23.6345 24 068335, as 059412 26 019910 PART NAME Lock Washer, 4 Plog [Nipple with Hex Nut, 3/8 (PDH Trucks Only) Reducer, 3/8 to 1/4 NPT (PDM Trucks Only) Switch Asy Half Nut, 3/8-16 Switch Adjustment Bracket Socket Hd Cap Serew, 1/4-20°x 3/8 Flat Ha Screw, 6-32 1-1/2 Washer Nut, 6-32 Strain Relief Bushing "Supplied with Item 19. No. REQD. REF REF A-8ars 51 ROUGH a associaTED (ico. Beowomonne s¥STEn, Figure6. Control Head Assembly, PDCB INDEX PART NO. INDEX PART NO. NO. "NO. PART NAME reas. | "No. "No. PART NAME REQD. 503835 Control Head Assembly 1 32° 059410 Hex Nut, 5.40 4 1900735 Sped Conta Switch 1 33 6st7T Rouen Matin Seem, 4 214 Spend Control Lever 1 40x 3) 3 assets Shaten Cone 2 34020668 Speed Control Harness 1 4 Ontos i 35052820 Connector Mounting Pate 1 $0750 Rall Retainer 1 36 020654 Pushbutton Switch 4 & 067412 Pan Head'Seen, S404 4 37008647" Connector Free Hanging 1 ose? 3116 da, 1 38 800216 —_‘Belyution Support Casting & ose inet 1 39800215 ——_—Bety-Bution Cartng 1 9 ord Phot hart i 4061018 Roll Pin, 14 31/2 2 10072415 Pam Hoad Screw, tread cutting, 2 41056583, Hoon Pusbuton 2 ‘eon 72 42° 089633 —Hex Lacknat, 236 3 02818 Switch Pate 1 43503798 ——_—Bely-Button Switeh and Harness 1 018203 PC. Boatd and Switch Asembly | Asem 058817 Switch Cam 1 44070486 Round Head Screw, 256 x3) 2 O7s073 Rerun Spring 1 45975310 ——_—Bell-Batton Sing 2 052819 Spring Retainer Spacer 1 46077209 Lack Washer, Spi 1/4 4 067413 Pan Head Seem S40 1/22 47053490 HextHead Screws 1/420.x34/4 52612 Switch Enetonste, Speed Control 1 46 018202 Inaator 1 ‘Switch ox 49 086581 Rate Pushbutton (optional) > 18069461 tar end Screw, S402 7 50 036582 Lower Pustbutton (optional) = 13039632, Hex Lacknut, 340 1 51 omold Wire 18 gu ark a ce 2 52 0s28l6 = Bctet i aoa acer ce eee 2 tm Ge 2] 8 tesee Retr maa t 23° 056579 Forward-Reverse Decal. 1 T Aw 066051 Drive Screw, No. 2, Type U, 4 8s beet Nut, Hex, 5-40 4 nee 56 068179 Screw, RU Ha, 5-40.x3/8 2 28 800217 ‘Switch Box, Left Side 1 $7 018202 Insulator, Switch 1 26 065484 Socket Head Cap Serew, 10-24 x 5/8 4 58 068177 Screw, RA, $40 x 3/8 2 21 800218 Switch Bor, Rae Sie i 59 400044 Bracket, Thermal Cutout 1 28 503796 Handle and'Tube Weliment = 60 020736 Thermal Cutout Switch 1 2 077207 Lock Washer, Spit, No. 10, 4 61 005433 Gonector, Splice 1 30 o67414 Pan ead Serem1Os0x 3/8 62 003643 Contact Pin 2 31077203 Lock Washer, Sit, No.s 4 63056491 Decal, Cold Conditioning Warning 1 *For reference only; part supplied with Part No. 020668. A ‘not shown) GENO479ADDPARTSs1 THROUGH 9 ASSOCIATED {Wit COLD CONDITIONING SYSTEM, wt Figure 7. Control Head Assembly, PDH INDEX PART NO. | INDEX. PART xo. Noe AS! PART NAME neab. | "NOX "AS! PARTNAME. ntob, 03835 Control Mead Ase 1 | soso exsuy 540 ‘ 1 900735 ‘Speed Control. ‘Switch 1 33° 068177 Round Head Machine Screw, 4 2 800214 ‘Speed Control Lever 1 5-40 x 3/8 aie fae eee 1] da ormses speed Cte Haren 1 oe i | is asze20 — Comecorouming Pate $ Ohaote Bet Reine Lf de Shaeeepattte i & 06012 ntead Stew, sox 4 | 3S Gaggere Button Set ' 7 053367 Ball Bearing, 3/16 dia. 1 is 800216, Belly-Button Support Casting 1 tes Seymeang ee I 9 074710 Pivot Shaft. 1 © 061018, Roll Pin, 1/4 x 3-1/2 lg, 2 10 CHAS anset ew rnd cuttng, 2 | dt Rluses dom Poatuce 3 40x 1/2, 2 059633 ‘Hex Locknut, 2-56. 2 tu osmme sucha 1 |B Sas RSVR Seth ana Marne Te n1s008 BR sana nemo | ‘seni (assy Santa ' 70486 Rounded Seew, 256x316 2 Bono Rene, | | Baie Bite pa 3 oe eee i | Gime Eeehwaue i Ie tees nawsowe, Saou 2 |S fess HESS aaa 1 GStel? Swan nee, SpeadConuar t | 43 SER Mex ten t ‘euch box @ O3658) Rate Rnuton opsonay 1g ossser atid Sowy, soci 7 |S taesen«— Rfuhtatonenenay, 3 a. ee > | oad weeciea an a 0s6s84 Brake Pushbutton, a 5 052816 Bracket. 1 torent Sut Rear Bracke i 2B os1502 2 | soe. Rea 2 2B 936579 1] oieese eco, s40 i Se eel Seer Rd ne 408378 5 as aaron anse 1 | oe tiem: Eton sean i 26 065454 Socket Head Cap Screw, 10-24 x 5/8 4 5 068177 Screw, Rd Hd, 5-40 x 3/8 2 2 Soons sues en Gp Ser {| 3 Soe Bacar'menar vane i 3% Stirs mnateand'ube etmens || g.—an0936——Thonal Gee Sune I ee t 50 erstg——Pintinacemntoaexia |G etan mmm b a 077203 Lock Washer, Split, No. S 4 6: 056491, Decal, Cold Conditioning Warning 1 ‘For reference only; part supplied with Part No. 020668. (PO shown) GENO0479ADD ASTareas rinouaiie AssooArco os Figure 8. Control Head Assembly, PDM_ INDEX. PART No. | INDEX. PART No. No. "NO. PART NAME rego. | 'No.” "No. PART NAME REQD. 503837 Control Head Asembh 1 33° 068177 Round Head Machine Screw, 4 1900734 "Speed Cantal Switch 1 ‘sao x 8 2 soo2i4 Speed Control Lever i 24 020668 Speed Control Harnes 1 3 asssi6 Switch Cover 35 052820 Connector Mounting ate 1 $ oner Spacer i 36 020658 ——_—Buahbutton Switch 4 Sansone Ball Retainer 1 37008687 Connector Free Hanging 1 & ogni Pan Head Screw, S40x 1/8 4 38 800216 ——BelvaButton Support Casting 1 5 asia Ball Bearing, 3/16 dia. 1 3900213 Bety-Button Casting 1 8 as3eis Spring Retainer 1 4061018 Rll Png 1x 4/2 2 8 o7n7i0 Prot Shaft 1 41056583 Hoon Pushbatton 2 1072414 Par Head Screw, thread cutting, 2 42059633 Hex Lockman, 256 a "40% 172 4350379 ——_eliy-Button Switch and Harness 1 1 ose Switch Pate 1 ‘Asm 12 organs PC. Board and Sich Asembly 1 44 070486 Round Head Screw, 2-56 x 3/4 2 1B assst7 Switch Cam 1 45078810 BeliyeButton Spring 2 14075073 ‘Return Spring 1 46077209 Lock Washer, Split, 1/4 4 1s as2si9 Spring Retainer Spacer 1 47 063490 Hex Head Ssrew, 1/4-20x 34/4 1 erat Pin Head Ser, S40x 1/22 48 018202 Insulator 1 17082812 Switch Enclosure, Speed Control $9 0s6581 Raise Pushbution (optional) 2 ‘Switsh Box 50086582 Lower Pushbutton optional). 2 18 069461 Flac Head Screw, $40 1/27 51 Osesa 3 1303962 Hex Lockout. 540 7 32 oszeie i 0 omms Finishing Washer 4 53 400s44 Resistor Bracket 1 1 Spacer or b 2 asso Gp 2 Sot Newly 540 ‘ 2B 086579 Forward Reverse Decal i a Saal ocenerf eens eeeon ee i 56 068179 Screw, RA Hd, 40x 9/8 2 SiG ig. ne 57 018202 Insulator, Switch 2 25 800217 Switch Box, Left Side 1 58 068177 Screw, Rd Ha, S40 x 3/8 2 26 063454 Socket Head Cap Serew, 10-24 x 5/8 4 59400044 Bracket, Thermal Cutout 1 27 $00218 Sitch Bor, Rig Side i 60 620736 Thermal Cutout Switch 1 28 503796 Handle and Tube Weldment 1 61 005433 Connector Splice 1 29° oma? Lack Water, Split. Nor 10 4 62 005643. Contact Bn 1 30067414 Pam Head Screw, 1-2003)8 63086491 Dacal,Cold Conditioning Waening 1 31077203. Lack Washer Spt, No.8 ‘ aoe 32059410 How Nuts S40 ‘ eu ae nn as *For reference only; part supplied with Patt No. 020668, GENO479ADDnitss2 ROUGH se associATED (ain COLD CONOTTONING SYSTEM. ove Figure 9. Control Head Assembly, PPT-30 INDEX PART No. DEX PART No. NO. NO. PART NAME reap. | /xo. NO. PART NAME, REQD. 503836 Contr! Head Assembly 1 33068177 Round Head Machine Sew, 4 1 300738 Speed Contol Switch 1 40x 318 2 so02i4 Speed Control Lever 1 34020668 Speed Contvol Harness 1 3 assis Switch Gover 2 38082820 Connector Mounting late 1 4 orenog Spacer 1 36 020654 Pushbutton Swatch 4 5 o7so7a it Retainer 1 37005687" Connector, Free Hangin 1 6 67412 Pan Head Stew, $40x 1/4 4 38 800216 Belly Bution Support Casting 7 083367 Ball Bearing, 3/16 da 1 39800215 Bly-Button Casting 1 & 052813 Spring Retiner 40 osi018 Roll Pin, 174 31/2 ip 2 9 onanio Prot Share 1 41056583 Horn Pushbutton 2 10 7414 PanHead Screw, thread cutting, 2 42039635, Hex Locknut, 256 2 ‘0% 1/2 43503795 Bely-Button Switch and Harness 1 11 oszeis Switch Plate 1 sembly 12 018203 P.-C. Board and Switeh Asembly 1 44070486 Round Head Screw, 256x 3/4 2 13055817 Switch Cam 1 45075510 ——_‘Bely-Button Spring 2 1078073 Return Spring 1 46 o77309 Lock Washer, Split, 1/4 4 15 s2ei9 Spring Retainer Spacer 1 47053490 HewHead Screw, 1/620x34/4 4 16 067413 Fan iead Screw, 540% 1/22 4801202 Insulator 1 17082612 Switch Enclose, Speed Control 1 49056581 Raise Pushbutton (optional) 2 Switch Box 50086582 Lower Pushbution (options) 2 18069461 Flat Head Serew, $40 1/27 Sl 056584 Brake Pushbutton 2 19059632 Hex Loeknut, 540 1 52052816 Bracket 1 2 ans ® Figure 10. Control Head Assembly, PPT-40 No. PART NAME REQD. ‘Control Head Assembly 1 ‘Speed Control Switch 1 ‘Speed Control Lever l Switch Cover 2 Spacer t Dall Retainer 1 Pan Head Serew, S-40x 1/4 4 Ball Bear 1 Spring Retainer 1 Phot Shaft 1 Pan Head Screw, thread cutting, 2 40x 172 Switch Pate 1 P.C. Board and Switch Assembly Switch Cam 1 Return Spring 1 1 2 1 Spring Retainer Spacer Pan Head Screw, 5-40°x 1/2 Switch Enclosure, Speed Control Switch Box Flat Head Screw, 5401/27 Hex Locknut, $40 1 Brake Pushbucton 2 Spacer 2 Gn 2 Forward-Reverse Deca 1 Drive Screw, No. 2, Type U, 4 S/16 le Switch Box, Left Side Socket Head Cap Screw, 10-24 x 5/8 Switch Box, Right Side Handle and Tube Weldment Lock Washer, Split, No. 10, Pan Head Serew, 10-24 x 3/8 Lock Washer, Split, No, § Hex Nut, 540 ference only; part supplied with Part No, 020668, INDEX. PART No. No. 3 ao 35 36 3 3a 39 40 41 a a 44 45 46 a 48 ° 50 Sh 52 3 54 55 56 37 38 59 60 61 62 63 “4 65 66 068177 920668 1052820 020654 503797 00216 800215 61018, 956583 059633, 503795, o70486 o7ssi0 orm 063490, 018202 056381 056582 o7aais 020699, ‘036580 018909 059632 068179 018202 068177 00084 020736 005433 005643 056491 023014 052816 4o0saa PART NAME REQD. 4 Round Head Machine Serew, 540x318 Speed Control Harness Connector Mounting Plate Pushbutton Switch Connector, Free Hanging Belly-Button Support Casting Belly-Button Casting Rol Pin, 1/4 3-1/2 lg, Horn Pushbutton Hex Lockenat, 256 Belly-Button Switch and Harnese Assembly Round Head Serew, 2-56 x 3/4 Belly-Button Spring Lock Washer, Split, 1/4 Hex Head Screw, 1/4-20 x 3-1/4 Insulator Raise Pushbutton Lower Pushbutton Pan Head Sere Rocker Switch Decal, Third Speed Resisior Nut, Hex, 540 Screw, Rd Hd, 5-40 x 3/8 Insulator, Switch Screw, Rd Hd, 5-40 x 3/8 ‘Thermal Cutout Cutout Switch Connector, Splice Contact Pin Decal, Cold Conditioning Warning (not shown) Wire, 18 ga. AIR Bracket 1 L GENO479ADDOda ‘wrestoig Buty feoENDoGE “TL aInB Ly 88 Ag GEN0479ADDHdd “wesdeiq Supt (e9EHAEF “ZL aN GEN0479ADD A107 Wad ‘wresseya Say OHNE “ET |mMB 2eseye wwe pny pig or Ad Aad GEN0479ADDOf Ldd “wesdeIC SUETM TeNDATT “pL INBLL f ERPRE a] FRR GENO479ADD AtaOr Lad “WeseIC SuBTAA WORNDOEE “STAINS ana el At3 GENO479ADDAn NOTES GENO479INSTNOTES GEN0479ADD A415AAG JL BIG) OE Big Joe Manufacturing Company 7226 North Kostner Avenue Lincolnwood, illinois 60646 GENO0479ADD