Big Joe PPT 45 Series Operation, Maintenance, Repair Parts
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Big Joe PPT 45 Series Operation, Maintenance, Repair Parts

Big Joe PPT 45 Series Operation, Maintenance, Repair Parts

Self-propelled pallet lift truck
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Manual No. 901336
PPT0104-901336
PPT 45 Series
Self-Propelled,
Pallet Lift Truck
Serial Numbers 373323
through 374781
Operation
Maintenance
Repair Parts List
i

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Summary of Contents for Big Joe PPT 45 Series

  • Page 1 PPT 45 Series Self-Propelled, Pallet Lift Truck Serial Numbers 373323 through 374781 Operation Maintenance Repair Parts List PPT0104-901336 Manual No. 901336...
  • Page 2 SAFETY SECTION SAFETY WARNINGS Energy Isolation Throughout this manual the following Warning Words During the servicing of the PPT 45 it may be required to will be used in conjunction with important operator work with and around electrical power. In most cases, instructions.

  • Page 3: Table Of Contents

    Table of Contents SECTION 1 DESCRIPTION 1-1. INTRODUCTION ............................1-1 1-2. GENERAL DESCRIPTION ..........................1-1 1-3. NAMEPLATE ...............................1-1 1-4. SAFETY FEATURES...........................1-2 1-5. OPTIONS..............................1-2 SECTION 2 OPERATION 2-1. GENERAL..............................2-1 2-2. OPERATING PRECAUTIONS ........................2-1 2-3. GENERAL CONTROL OPERATION ......................2-2 2-4. DRIVING AND STOPPING PROCEDURES ....................2-2 2-4.1.
  • Page 4 4-4.4. Replacement of Dead-Man Switch ....................4-12 4-4.5. Replacement of Creep Travel Switch ..................... 4-12 4-4.6. Replacement of Control Arm Shock Absorber................4-13 4-5. DRIVE MOTOR, TRANSMISSION, DRIVE WHEEL, AND PIVOT TUBE ASSEMBLY ......4-13 4-5.1. Drive Motor Servicing........................4-13 4-5.2.
  • Page 5 SECTION 6 TROUBLESHOOTING 6-1. TROUBLESHOOTING CHART ........................6-1 6-2. Contactor Testing ............................6-3 6-2.1. Contactor Testing ..........................6-3 6-2.2. Switch Testing..........................6-3 6-3. TRANSISTOR CONTROLLER TROUBLESHOOTING ................6-5 6-3.1. Circuit Operation..........................6-6 6-3.2. GENERAL SYSTEM CHECKOUT....................6-9 6-3.3. ADJUSTMENT ..........................6-10 6-4. DIAGNOSTICS............................6-11 6-4.1. Programmer Diagnostics ........................6-12 6-4.2.
  • Page 6 PPT0104-901336...

  • Page 7: Section 1 Description

    By following the recommendations contained in this • Model number manual, you will receive many years of dependable service from your Big Joe lift truck. • Serial number • Maximum capacity, load center, and maximum 1-2. GENERAL DESCRIPTION...

  • Page 8: Safety Features

    1-4. SAFETY FEATURES 1-5. OPTIONS The PPT 45 is designed and engineered to provide Big Joe offers options and accessories for the PPW 45 maximum safety for operator and payload. Some of the lift truck such as: safety features incorporated into the design are: •...

  • Page 9: Section 2 Operation

    Section 2 OPERATION 2-1. GENERAL 4. Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at This section gives detailed operating instructions for cross aisles and wherever vision is obstructed. the PPT 45 lift truck. The instructions are divided into the various phases of operations, such as operating lift, 5.

  • Page 10: General Control Operation

    2-3. GENERAL CONTROL OPERATION The speed control (Figure 2-1), located on each side of 4. To slow down or stop, release the speed control the control head, provides fingertip control for driving and lower or raise the steering arm to the the truck.

  • Page 11: Belly-Button Switch. (Figure 2-1)

    2-5. BELLY-BUTTON SWITCH. (FIGURE 2-1) 2-8. LOADING AND UNLOADING The belly-button switch (Figure 2-1) minimizes the 1. Move truck to location where load is to be picked possibility of the driver being pinned by the steering arm while driving the lift truck forward in slow speed. If 2.
  • Page 12 NOTES: PPT0104-901336...

  • Page 13: Section 3 Maintenance

    Section 3 MAINTENANCE 3-1. GENERAL 3-4. BATTERY CARE Maintenance includes both the operator daily check procedures and scheduled maintenance, which must be performed by a qualified service technician. Any WARNING problems noted during the operator's daily inspection or the monthly and quarterly scheduled maintenance procedures must corrected...
  • Page 14 Table 3-1. Daily Checks VISUAL CHECKS ITEM PROCEDURE DAMAGE Check for bent, dented or broken parts. LEAKS Check drive unit and hydraulic system. TIRES AND WHEELS Check drive wheel and load wheels for wear, damage, binding, etc. FORKS Check for bends and misalignment. CABLES AND HOSES Check that they are in place and not damaged.

  • Page 15: 3-4.2 Battery Removal

    Table 3-2. Monthly and Quarterly Inspection and Service Chart NOTE: The following service checks should be performed by a qualified service technician. INTERVAL INSPECTION OR SERVICE Monthly Clean drive motor and check condition of commutator, brushes, and springs (Section 4-5). Monthly Clean hydraulic pump motor and check condition of commutator, brushes, and springs (Section 4-8).

  • Page 16: Lubrication

    (See Table 3-4 for Application) I-7044 No. 1 Transmission oil - EP SAE 80W-go. Capacity - 1.5 quart. Big Joe No. 055780 (Replace with 055790. 1W-30, if cold Figure 3-1. Lubrication Locations conditioning option for continuous operation below 320F is installed).
  • Page 17 Table 3-4. Lubrication Chart Figure 3-1 Method Of Type Time Interval Location Application of Lubricant Index Application (Table 3-4) Semi-Annually Steering Arm Oil Can No. 4 1 or 2 drops each time serviced Elbow Annually Transmission No. 1 Fill to plug level Housing Semi-Annually Hydraulic...
  • Page 18 NOTES: PPT0104-901336...

  • Page 19: Section 4 Adjustment And Repair

    Catch Parts listings are provided in Section 7 of this manual. the springs while pulling the casting away The parts list provides the Big Joe Manufacturing to prevent their loss. Company part number, the part description, and the 3.

  • Page 20: 4-3.2 Potentiometer Testing And Adjustment

    4. Reinstall belly-button casting, making certain all 4. Disconnect the connector round located at parts are back in place. Check operation of the contactor panel, connecting the control cable and belly-button safety switches by pressing the belly- wire harness. Set an ohmmeter to the RXIK (1000) button casting while listening for the 'click' that scale and connect across pin contacts of wires 7 indicates that the switches have actuated.

  • Page 21: 4-3.3 Control Head Switch Replacement

    High Speed Cutout Switch Assembly Push Button Switch Assembly I-7007 Figure 4-2. Control Head Assembly 4-3.3 Control Head Switch Replacement 1. Disconnect the battery. Control NOTE: Access to belly-button switches (5, Figure Head 4-2) is provided by removal of safety cover (54).

  • Page 22: 4-3.4 Steering Arm

    b. Tag and disconnect electrical wires from Install top cover (66) and secure with screws bellybutton switchs. (64). c. Connect electrical wires to new belly-button m. Install bottom cover (40) and secure with switchs, as noted during removal. screws (20). d.

  • Page 23: 4-3.5 Steering Arm Spring Replacement

    alignment match mark to assist in re- installation. e. Insert a 5/16 inch Allen wrench through hole in bottom of steering arm (25, Figure 4-4). Loosen and remove screw (20) and spacer (19). IMPORTANT Unless properly supported, steering arm (2) will drop out of the steering tube when the spring tube (25, Figure 4-4) is removed.

  • Page 24: 4-3.6 Electrical Control Cable Replacement

    o. Refer to paragraph 4-3.4, step 1, above, and, if necessary, adjust the tension on steering arm return spring. p. Reconnect battery. 4-3.6 Electrical Control Cable Replacement. 1. Disconnect battery. 2. Remove screws (66, 67 and 68, Figure 4-6), lock- CRIMP ON BRAKE washers, flat washers, and motor compartment WIRE POS &...
  • Page 25 I-7059 Figure 4-6. Motor Compartment Service Covers 16. Secure one end of the braided fabric sleeve to the 18. Pivot transmission through entire turning range, cable bundle with electrical tape. Pull the fabric make sure that all electrical cables and wire leads sleeve taught and securely tape the remaining end will flex properly and not become caught or of the fabric sleeve to the cable bundle with...

  • Page 26: Brakes

    HOUSINGS 004705 CABLE WIRE COLOR PIN NO. WIRE NO. BLACK BLUE CONTACT-SOCKET SEE CHART FOR ORANGE PIN CONNECTIONS YELLOW BROWN RED W/BLACK STRIPE BLUE W/BLACK STRIPE LOOSE SOCKET WIRES - ORANGE W/BLACK STRIPE CONNECT ACCORDING TO CHART YELLOW W/BLACK STRIPE BROWN W/BLACK STRIPE BLACK W/RED STRIPE CONNECTOR...

  • Page 27: 4-4.2 Brake Pad Replacement

    7. Adjust the air gap between the armature plate (2, Figure 4-9) and the stator (1) using the three hexagon screws (3). Using standard feeler gauges, adjust to achieve the dimension "SLU" at each hex nut, which sets the gap for the armature plate (Table 4-1).
  • Page 28 4. Remove the four screws (1) securing the guard 9. Remove and replace the friction plate (4) and ring (3) and slide the guard ring upwards as much brake hub (3) assemblies. as possible. CAUTION Removing the mounting screws will loosen the steering arm.

  • Page 29: 4-4.3 Replacement Of Brake Assembly

    4-4.3 Replacement of Brake Assembly 7. Trace the wire harness to the Creep and Deadman switches. 1. Disconnect battery. 2. Jack up the truck so the drive wheel is off the ground; then securely block the truck to prevent IMPORTANT movement.

  • Page 30: 4-4.4 Replacement Of Dead-Man Switch

    4-4.4 Replacement of Dead-Man Switch 1. Disconnect the battery. 2. Block the wheels to prevent the truck from rolling. 3. Remove the steering tube cover plate (2, Figure 4- 4. Remove the switch mounting bracket mounting screws (3, Figure 4-13). NOTE: When standing at the control head, the Dead Man Switch is located on the right hand side of the steering tube.

  • Page 31: 4-4.6 Replacement Of Control Arm Shock Absorber

    9. Reinstall switch mounting bracket onto steering tube. IMPORTANT Make sure not to pinch any of the wires when reinstalling the mounting bracket. 10. Reinstall steering tube cover plate. 11. Reconnect battery, remove wheel blocking and test I-7018_1 operate truck to verify dead-man switch operation. Figure 4-15.

  • Page 32: 4-5.3 Inspect Commutator Assembly

    IMPORTANT Make sure that the brush spring is not removed from the support pin or allowed to unwind. 5. Install new brush, reseat brush spring and secure the electrical lead. 6. Repeat Steps 3 and 4 for remaining brushes. 4-5.3 Inspect commutator assembly. If the brushes are not worn and the motor does not run, inspect the commutator for wear or damage as follows: 1.

  • Page 33: 4-5.4. If The Motor Needs To Be Replaced, Remove It From The Transmission As Follows

    IMPORTANT Make sure to remove the spring washer (13) and save for reassembly. 10. Remove all brushes (12). 11. Remove the brush box assembly (10) and brush springs (11). 12. Inspect the commutator assembly (14) for signs of wear or burns. If the commutator shows signs of wear, use fine sandpaper to resurface commutator contact surfaces.

  • Page 34: 4-5.5 Transmission Assembly Removal

    17. Reconnect the four cables to the drive motor. Make sure to match the cable label to the terminal. IMPORTANT CAUTION Note the location and routing of the control cables for the reassembly process. Make sure that wires do not contact sharp edges of any assembly.

  • Page 35: Base, Frame And Fork Section

    NOTE: If the load wheel is worn to approximately 1/8" thickness or is cracked or damaged, replace the wheel and bearing assembly. Big Joe recommends that both load wheel assemblies be replaced at the same time. a. Partially insert the load wheel shaft (5) into the load wheel housing (1).

  • Page 36: 4-6.3 Frame Assembly: Fork Section And Lift Linkage Repair And Replacement

    b. Pull wheel housing out of fork section to gain access to the keeper pin (5). Remove lock screw and keeper pin (5). c. Drive out roll pin (2) from shaft (7). Remove shaft from the power section end of the pull rod.
  • Page 37 THREADED STUDS WELDED TO MOTOR COMPARTMENT WALL. CONTROLLER I-7049 Figure 4-22. Lift Link Assembly 3. Power Section Frame Repair: a. Repair of power section frame is limited to chasing damaged threads and welding of any broken welds. b. Replace a worn or damaged U-clip nuts as needed.

  • Page 38: Electrical

    4-7. ELECTRICAL 4-7.2 Battery Cable Assemblies Replacement. 1. Disconnect batteries (Section 4-7.1). 4-7.1 Battery Removal and Replacement 2. Trace the cable (1, Figure 4-24) that needs to be 1. The batteries enclosed in the battery replaced from the battery compartment into the compartment.

  • Page 39: 4-7.3 Transistor/Contactor Panel

    Two 12V batteries with charger built into truck Four 6V batteries with charger built into battery pack Single 24V (flooded cell) industrial battery I-7027 Figure 4-23. Battery Installation 4-7.3 Transistor/Contactor Panel NOTE: Erratic operation of the truck may be caused by defective controller components.

  • Page 40: 4-7.4 Horn Replacement

    2. Contactor Panel Disassembly 4-7.4 Horn Replacement. To replace the horn, proceed as follows: a. Refer to Figure 4-27 for the location and identity of the major replacement components 1. Tag and disconnect all electrical connections from mounted on the panel and remove defective horn..

  • Page 41: 4-7.5 Battery Charger

    I-7030 Figure 4-27. Contactor Panel Replacement Parts 4-7.5 Battery Charger. 4-7.5.2 Medium Duty 6V Battery Pack NOTE: If the lift truck is equipped with a heavy duty The medium duty battery pack is a self contained unit 24V steel case flooded cell industrial battery, with batteries and charger built into the battery case.

  • Page 42: 4-7.6 Battery Discharge Indicator

    Set dip switches on charger logic board as required by battery configuration Default setting - Gel Cell (GMF) Batteries Absorbed Glass Mat Cell (AMF) Batteries Flooded Cell Battery Two 12V Batteries W/truck Mounted Charger Four 6V Battery Pack and Charger I-7032-2 Figure 4-28.

  • Page 43: 4-7.7 Hourmeter

    2. To replace the battery discharge indicator (1), 4-7.7.1 Hour meter Replacement. proceed as follows: 1. Operation of the hour meter (2) may be checked against a watch. a. Disconnect the battery. b. Tag and disconnect terminals behind the 2. To replace the hour meter (2), proceed as follows: indicator.
  • Page 44 I-7038 Figure 4-30. Electrical Schematic 4-26 PPT0104-901336...

  • Page 45: Hydraulics

    4-8. HYDRAULICS. 4. Refer to Figure 4-31 and remove leaking line (2) or fitting and replace it with a new line or fitting. 4-8.1 Line and Fitting Replacement. 5. Remove the vent plug and elbow (5 & 6, Figure 4- 31).
  • Page 46 DANGER • Hydraulic oil under pressure can penetrate the skin. It is toxic and can damage tissue. Always use a piece of wood or cardboard to check for suspected hydraulic leaks. NEVER YOUR HANDS. Obtain immediate medical attention from a medical provider knowledgeable with hydraulic fluid injuries if pressurized hydraulic fluid pierces the skin.

  • Page 47: 4-8.3 Lift Cylinder Removal

    4-8.3 Lift Cylinder Removal. 4-8.4 Lift Cylinder Repair. 1. Disconnect batteries. To rebuild or replace components in a lift cylinder, proceed as follows: 2. Lift complete truck to height sufficient to permit access to under side of hydraulic cylinder (1, 1.

  • Page 48: 4-8.5 Hydraulic Pressure Adjustment

    2. Remove motor compartment (service) cover. surfaces to be painted. Touch up paint on frames and pull rods with yellow enamel (Big Joe P/N 901201). 3. Disconnect hose (2, Figure 4-31) from elbow (9, Touch up paint on remaining parts with black satin Figure 4-32) at pump and connect a pressure enamel (Big Joe P/N 901202).

  • Page 49: Section 5 Options

    Section 5 OPTIONS 5-1. COLD CONDITIONING PACKAGE. control head and deadman switch as shown in Figure 5-1. For intermittent operation under 32° F, the oils and Continuous operation of the PPT lift trucks at grease need not be changed. Refer to the wiring temperatures below 32°...
  • Page 50 NOTES: PPT0104-901336...

  • Page 51: Section 6 Troubleshooting

    Section 6 TROUBLESHOOTING 6-1. TROUBLESHOOTING CHART MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION Truck will not run, lift system does a. 120 AMP fuse blown Check fuse Replace if necessary not operate. b. Battery dead or disconnected. Check battery and quick disconnect (Section 4-7.1) c.
  • Page 52 MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION Squealing sounds when lifting a. Oil level too low. Add oil to reservoir.Apply grease. forks. b. Lift linkage binding. Lift carriage does not lift to top. Oil level too low. Add oil to reservoir Weak, slow or uneven action of a.

  • Page 53: Contactor Testing

    6-2. CONTACTOR TESTING NOTE: Testing of the reverse contactor is shown in Figure 6-1. Make certain battery is in good condition and fully charged before beginning tests. 5. If the truck is equipped with a keyswitch, turn it on and place the steering control in the run position 6-2.1 Contactor Testing (brake off) and depress the speed control, 1.
  • Page 54 4. If the truck is equipped with a keyswitch, turn it on, 6. If resistance is present (10 ohms or more), the lower the control handle to the driving position and switch or wiring leading to the connector is depress the suspect switch. defective and must be repaired or replaced.

  • Page 55: Transistor Controller Troubleshooting

    6-3. TRANSISTOR CONTROLLER TROUBLE- SHOOTING The basic Big Joe Transistor Controlled Electrical System is shown in schematic form in Figure 6-3. Refer to the wiring diagrams included in Chapter 4 for complete wiring diagram for this truck. Refer to these diagrams and the schematic for tracing of electrical circuits during troubleshooting and testing procedures.

  • Page 56: 6-3.1 Circuit Operation

    The battery only has to supply a fraction of the current The Big Joe custom transistor controller allows that would be required by a conventional controller superior control of the vehicle's drive motor speed.
  • Page 57 4. Current Limiting. Table 6-1. Controller Specifications. The transistor controllers limit the motor current to Big Joe Model 90 /200-02 a preset maximum. This feature protects the con- Input Voltage troller from damage that might result if the current were limited only by the motor demand.
  • Page 58 The controller returns to normal operation grammer (Part Number 005472-02) is available when the fault (e.g., accelerator wiring, broken through your Big Joe dealer. If you require dealer connectors, potentiometers that fail or are set to location information, contact Big Joe Manufactur- start at 0) has been corrected.

  • Page 59: 6-3.2 General System Checkout

    14. Emergency Reverse: Enhanced Plugging Current. Emergency reverse (or "belly button") switches are mounted on the handles of walkie vehicles. The CAUTION emergency reverse switch is wired to the controller and other vehicle electronics in such a way that if the button is pressed against the operator by the advancing vehicle,...

  • Page 60: 6-3.3 Adjustment

    7. Take the vehicle off the blocks and drive it in a clear area. It should have smooth acceleration and good top speed. 8. Test the plug braking of the vehicle. The vehicle should smoothly slow to a stop and reverse direction, with the audible plugging tone.

  • Page 61: Diagnostics

    6-4. DIAGNOSTICS. by two flashes is code "3,2" appears in the LED code table as: The motor controller provides diagnostics information to assist in troubleshooting drive system problems. The 000 00 000 00 000 00 diagnostics information can be obtained in two ways: (3,2) (3,2) (3,2)

  • Page 62: 6-4.1 Programmer Diagnostics

    6-4.1 Programmer Diagnostics To clear the diagnostic history file, select: With a programmer, diagnostics and troubleshooting is Faults->Clear Fault History. more direct than with the LED alone. The programmer You will be asked to confirm your actions. Use the presents complete diagnostic information in plain "plus"...

  • Page 63: 6-5.1 Cleaning

    6-5.1 Cleaning 6-6. TROUBLESHOOTING The following procedures are to fix vehicles that will not operate properly. Refer to the basic wiring schematic (Figure 6-3) when conducting these tests. Make sure IMPORTANT the controller is hooked up as shown in Figure 6-4. Refer to the wiring diagram and schematic for your vehicle.

  • Page 64: 6-6.1 Check For Power To The Controller

    6-6.1 Check for Power to the Controller 6-6.2 Check for Contactor Operation and Key- switch Input (KSI) 1. Leave the keyswitch off for these tests (if truck is 1. If the truck is equipped with a power key, turn the so equipped).

  • Page 65: 6-6.4 Check For Controller Output

    2. If these resistance readings are wrong, it is 4. The next step is to measure the current in the because the potentiometer itself is either: controller's M- lead. If you have a means of measuring this high dc current, such as a shut/ •...
  • Page 66 NOTES: 6-16 PPT0104-901336...

  • Page 67: Section 7 Parts List

    Section 7 PARTS LIST PPT0104-901336...

  • Page 68: Control Head Assembly

    7-1. CONTROL HEAD ASSEMBLY High Speed Cutout Switch Assembly Push Button Switch Assembly I-7007 Figure 7-1. Control Head Assembly PPT0104-901336...
  • Page 69 INDEX PART NO. PART NAME REQD. 505360-04 Control Head 005652 Pin Housing Not Used 017580 Potentiometer 018202 Switch Insulator 020669 Micro Switch 505323 Wire Harness Assembly 020775 Micro Switch 052956 Flanged Bearing 053366 Return Spring 056131 Hose Clamp 056617 Forward-Reverse Decal 057262 Potentiometer Disk 059633...
  • Page 70 7-1. CONTROL HEAD ASSEMBLY (CONTINUED) High Speed Cutout Switch Assembly Push Button Switch Assembly I-7007 Figure 7-1. Control Head Assembly PPT0104-901336...
  • Page 71 INDEX PART NO. PART NAME REQD. Not Used 077204 Split Lock Washer #6 400546 Connector Rod Assembly 402827 Shaft 402828 402830 Bottom Cover 403358 Tube 074724 Spacer 402836 Spacer 402837 Bracket 402839 Tube 402840 402841 Handle Guard 402843 504538-01 Wire Assembly 505052 Switch Bracket Assembly 066052...

  • Page 72: Steering Arm

    7-2. STEERING ARM I-7057 Figure 7-2. Steering Arm Assembly PPT0104-901336...
  • Page 73 Item Qty. Part No. Description 506124-01 Control Head 800310 Steering Arm 065481 Screw, Cap, Socket Head 404196 Cam, Deadman Switch Not used 065530 Screw, Cap, Button Head, Nylok 074451 Shock Absorber 065472 Screw, Cap, Socket Head 020775 Switch, Micro 404210 Plate, Mounting, Micro Switch 077209 Washer, Lock...

  • Page 74: Power Section Parts

    7-3. POWER SECTION PARTS TO DRIVE MOTOR TO CONTACTOR PANEL 30, 26 I-7057 Figure 7-3. Power Section Parts PPT0104-901336...
  • Page 75 Item Qty. Part No. Description 504364 Clamp Assembly, Clinch Nut 404220 Ring Guard 506146 Hydraulic Cylinder 506142 Pin - Keeper 059421 Nut - Hex, ¼-20 UNC 075620 Stud, Threaded ¼-20 x 1¼ Lg 056135 Clamp - Cable, Cushioned 077209 Washer - Lock, ¼ Not Used 065557 Screw-SHCS, 5/16-24 UNF x 1¾...
  • Page 76 7-3. POWER SECTION PARTS (CONTINUED) TO DRIVE MOTOR TO CONTACTOR PANEL 30, 26 I-7057 Figure 7-3. Power Section Parts 7-10 PPT0104-901336...
  • Page 77 Item Qty. Part No. Description 504312-15 Hose Assembly - 3/8 023270 Wire Harness Assembly, Hydraulic 016594 Pump, Motor & Reservoir Assembly - 24 V 504116 Suppressor Assembly - Spike, Lower Solenoid 504097 Suppressor Assembly - Spike, Motor Solenoid 077056 Washer - Flat, 3/8 077211 Washer - Lock, 3/8"...

  • Page 78: Transmission, Motor And Brake Assembly

    7-4. TRANSMISSION, MOTOR AND BRAKE ASSEMBLY I-7051 Figure 7-4. Transmission, Motor and Brake Assembly 7-12 PPT0104-901336...
  • Page 79 Item Qty. Part No. Description 901700 Screws (Set of 3), Brake Assembly Mounting 901701 Stator, Brake 901702 Rotor, Aluminum 901703 Plate, Friction 901704 Cover, Brake 901705 Clip, Spring 901706 Woodruff Key 901707 Gear, Splined 067435-01 Screw, Allen Head, Countersunk, Metric, M8 x 1.25 x 35 Lg 404189 Motor End Plate 901708...

  • Page 80: Drive Motor Repair Parts

    7-5. DRIVE MOTOR REPAIR PARTS I-7022 Figure 7-5. Drive Motor Repair Parts 7-14 PPT0104-901336...
  • Page 81 Item Qty. Part No. Description 016051 Motor, Drive 901722 Clip, Spring 901723 Woodruff Key 901724 Gear, Splined 067435-01 Allen Head Countersunk Screw, Metric 404189 Motor, End Plate 901725 Bolt, Hex Head, 901726 Head, Commutator End 901727 Brush Lead and Terminal Connector 901728 Bearing, Commutator End 901729...
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  • Page 83: Base And Frame Parts

    7-6. BASE AND FRAME PARTS Figure 7-6. Base Frame and Parts Item Qty. Part No. Description 065531 Screw-BHCS, #10-32 UNC x ½ Long 404221 Cover, Brake 404220 Ring, Guard 059940-01 Nut, Retainer, ¼-20 065525 Screw-BHCS, ¼-20 UNC x 5/8 Long 506144 Cover, Main 065527...

  • Page 84: Fork Section Parts

    7-7. FORK SECTION PARTS THREADED STUDS WELDED TO MOTOR COMPARTMENT WALL. CONTROLLER I-7049 Figure 7-7. Fork Section Parts 7-18 PPT0104-901336...
  • Page 85 Item Qty. Part No. Description 403980 Shaft - Pivot 061200-03 Spring, Pin - Slotted, .19 x 1¼ Long 077036 Washer - shim, 1.25 OD x .766 ID 506129 Load Wheel and Housing Assembly 506147 Pin, Keeper 506135- Tie Rod Assembly - 48" ForkTie Rod Assembly - 42" ForkTie Rod 01506135- Assembly - 36"...
  • Page 86 THIS PAGE INTENTIONALLY LEFT BLANK 7-20 PPT0104-901336...

  • Page 87: Hydraulic Cylinder Parts

    7-8. HYDRAULIC CYLINDER PARTS I-7052 Figure 7-8. Hydraulic Cylinder Parts Item Qty. Part No. Description 506154 Hydraulic Cylinder Assembly 901735 O-ring 901736 O-ring 901737 Seal, 901738 Seal, 025716 Grease Fitting, Straight, ¼-28 NPT 026922 Fitting, Hydraulic, 9/16-18 SAE, 9/16-18 JIC 901739 Packing Kit PPT0104-901336...
  • Page 88 7-9. HYDRAULIC CYLINDER PARTS I-7058 Figure 7-9. Hydraulic Pump, Motor and Reservoir Assembly Parts 7-22 PPT0104-901336...
  • Page 89 Index PartNo. Part Name 901432 Cap/Brush Kit 901433 24V Motor 901434 Motor Adapter 901437 Adapter-Pump-Res Kit 025535 9/16 Elbow 901442 Relief Valve Assy 901440 Filter 901441 Reservoir 026703 Elbow 076701 Breather Plug 901439 Coupling 901438 O-Ring 901436 Check Valve 048133 Solenoid Release Valve 901435 Flow Regulator...

  • Page 90: Battery Installation Parts

    7-10. BATTERY INSTALLATION PARTS TO BATTERY CHARGER TRANSFORMER 36, 38 31 32 33 36, 39 I-7054 Figure 7-10. Battery Installation Parts 7-24 PPT0104-901336...
  • Page 91 Item Qty. Part No. Description 506152 Cover, Battery Not Used 506123-01 Cable Assembly - Battery, 4 AWG 505469-05 Cable Assembly - Battery 505469-06 Cable Assembly - Battery 505627-03 Connector Assembly, Battery 005454 Connector, Inlet, Flanged 010614 Standoff, Insulator 057519 Grommet 077105 Washer, Flat, ¼, Brass 068478...

  • Page 92: Battery Charger Assembly

    7-11. BATTERY CHARGER ASSEMBLY 22, 23, 24 10 - POSITION WINDOWS IN DECAL OVER LED's 11, 12 6, 7, 8 3, 4, 5 26, 27, BATTERY TYPE DIP SWITCH SETTING DETAIL (GELL CELL MODE) I-7063 Figure 7-11. Battery Charger Assembly 7-26 PPT0104-901336...
  • Page 93 Item Qty. Part No. Description 404305 Housing, Battery 403688 Spacer, Connector 068478 Screw, SLRH, ¼-20 x 1 ¼" Lg 077209 Washer, Lock, Split, ¼" 059421 Nut, Hex, ¼-20 071376 Screw, PHTH, 10-32 x ½" Lg 077208 Washer, Lock, Split, #10 059416 Nut, Hex, #10-32 506122...

  • Page 94: Contactor Panel Assembly Parts

    7-12. CONTACTOR PANEL ASSEMBLY PARTS 6 - CABLE F2 - 6 - CABLE F1 - TO DRIVE MOTOR TO DRIVE MOTOR 24, 22, 20 10, 11 23, 37 32, 22, 23, 37 35, 36 5 - CABLE TO HYD 25, 23, 21 PUMP/MOTOR 27, 19, 18 CABLE TO HYD...
  • Page 95 Item Qty. Part No. Description 504150-17 Cable Assembly - #4 AWG 504150-25 Cable Assembly - #4 AWG 504150-26 Cable Assembly - #4 AWG 504150-27 Cable Assembly - #4 AWG 505181-07 Cable Assembly - #4 AWG 504150-28 Cable Assembly - #4 AWG 505466-01 Battery Connector Assembly 005468...

  • Page 96: Charger Circuit Board

    7-13. CHARGER CIRCUIT BOARD WIRE #18 (WHITE) TO TRANSFORMER-SEE DIA RED WIRE (NO NUMBER) TO TRANSFORMER-SEE DIA WIRE #16 (WHITE) TO TRANSFORMER-SEE DIA WIRE #17 (WHITE) TO TRANSFORMER-SEE DIA BLACK WIRE (NO NUMBER) TO TRANSFORMER-SEE DIA BATTERY CHARGER (REF) SEE ORDER ENTRY FORM SET DIP SWITCHES ON CHARGER LOGIC BOARD AS REQUIRED: 506149-01 DEFAULT SETTING-GEL (GMF) 506149-02 ABSORBED GLASS MAT (AMF)

  • Page 97: Load Wheels

    7-14. LOAD WHEELS I-7046 Figure 7-14. Load Wheel Item Qty. Part No. Description 506128 Weldment- HSG, Wheel 505709 Load Wheel Assembly 077033 Washer, Flat, 1.02 ID, 2.5 OD 403687 Shaft - Axle 506147 Pin- Keeper 077209 Washer Lock, 1/4" 065476 Screw - HHCS, ¼-20 UNC x 1/2"...

  • Page 98: Optional Equipment

    7-15. OPTIONAL EQUIPMENT 7-15.1 Cold Conditioning I-7060 Figure 7-15. Cold Conditioning Parts 7-32 PPT0104-901336...
  • Page 99 Index Qty. Part No. Description 056491 Decal, Cold Conditioning 018909 10 0hm, 20 Watt Heat 068186 Screw 400544 Bracket, Resistor Mounting 018214 Insulator 402829 Bracket 077007 Washer 077204 Washer, Lock 072400-01 Screw 400044 Bracket, 1 403372 Insulator 059632 Nut, Lock 020736 Switch, Thermal 005643...
  • Page 100 NOTES: 7-34 PPT0104-901336...
  • Page 101 PPT0104-901336...
  • Page 102 Big Joe Manufacturing Company - Lincolnwood, IL 60646 PPT0104-901336 Manual Price: $35.00...

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