Big Joe PTE 30 Series Operation, Maintenance, Repair Parts List Download Page 68

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12-4

901467

Figure 12-2 Steering Arm

R6507

Summary of Contents for PTE 30 Series

Page 1: ...Big Joe Manufacturing Company Des Plaines IL 60018 MANUAL NO 901467 06 20 2017 PTE 30 SERIES SELF PROPELLED PALLET LIFT TRUCK Operation Maintenance Repair Parts List...

Page 2: ...brake smoothly Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or overturn Use special care when traveling without load as the risk of overturn may be greater Al...

Page 3: ...ETER REMOVAL TESTING AND ADJUSTMENT 5 4 5 1 6 CONTROL HEAD INSTALLATION 5 5 5 2 STEERING ARM 5 5 5 2 1 PNEUMATIC SPRING REPLACEMENT 5 5 5 2 2 STEERING ARM REMOVAL 5 5 5 2 3 STEERING ARM INSTALLATION 5...

Page 4: ...5 1 CONTROL HEAD SWITCHES 5 2 5 2 CONTROL HEAD AND STEERING ARM 5 3 5 3 DRIVE CONTROLS 5 4 5 4 STEERING CONTROL 5 6 6 1 TRANSMISSION BRAKE AND DRIVE MOTOR ASSEMBLY 6 1 7 1 DRIVE ASSEMBLY 7 2 7 2 FORK...

Page 5: ...elf propelled PTE 30 truck Figure 1 2 lifts and transports payloads up to 3000 pounds on rigid forks The forward and reverse motion is controlled by either of two controller levers mounted on the cont...

Page 6: ...bstruction when backing up in slow speed All control functions automatically return to OFF when released Externally accessible emergency disconnect switch within operator s reach Separately fused cont...

Page 7: ...veling without load as the risk of overturn may be greater Always look in direction of travel Keep a clear view and when load interferes with visibility travel with load or lifting mechanism trailing...

Page 8: ...ls on control head operate in all speed ranges in forward and reverse and that belly button switch functions Wheels Check drive wheel for cracks or damage Move truck to check load for freedom of rotat...

Page 9: ...eck Off List Date Big Joe Manufacturing Company Operator Truck No Model No Dept Check Tires Load Wheels Horn Lift Lower Control Need Maintenance O K Shift Hour Meter Reading Drive Hoist Attachment Ope...

Page 10: ...and pull the emergency disconnect switch out Grasp the grips of the steering head so that the speed control can be comfortably operated by either thumb 2 Lower the steering arm to a comfortable positi...

Page 11: ...R button and hold until forks descend to desired height 2 9 LOADING AND UNLOADING 1 Move truck to location where load is to be picked up 2 Move the truck into position so forks are within pallet or sk...

Page 12: ...2 6 901467 NOTES...

Page 13: ...s will vary depending on depth of discharge and temperature Follow safety rules when placing a battery on charge Proceed as follows 1 Park truck at charging station with carriage low ered and key swit...

Page 14: ...780 Transmission oil EP SAE 10W 30 Part Number 055790 Note No 2 Grease Lithium base general purpose Part Number 055750 Part Number 055753 Note No 3 Hydraulic oil Heavy duty with a viscosity of 150 SUS...

Page 15: ...drops each time serviced 2 Lift Linkage Can No 4 1 or 2 drops each time serviced 3 Lift Linkage Fittings Gun No 2 Pressure lubricate 4 Entry Rollers Can No 3 1 or 2 drops each time serviced 5 Load Whe...

Page 16: ...3 4 901467 NOTES...

Page 17: ...ermine if it is malfunctioning d Defective wiring Check for open circuit Repair as required TROUBLE WITH TRAVEL Truck does not run forward or reverse All other functions oper ate normally a Check all...

Page 18: ...n action of hydraulic system a Defective pump or relief valve Check pressure Adjust as neces sary b Worn lift cylinder Repair or replace cylinder c Load larger than capacity Refer to I D platefor capa...

Page 19: ...ting in hydrau lic line and repair as required Replace lift cylinder or valve assembly 21 Figure 12 14 MISCELLANEOUS Steering arm does not return to the upright position a Week pneumatic spring Replac...

Page 20: ...Figure 4 1 for LED location on controller The diagnostic codes flashed by the LED are listed in Table 4 3 If the fault is critical the controller is automatically dis abled Faults can be caused intern...

Page 21: ...des information about only the currently active faults 4 2 4 Fault Recovery Almost all faults require a cycling of the KSl Key Switch Input or brake input to reset the controller and enable operation...

Page 22: ...ake emergency reverse and mode switches Cycle each switch in turn observing the programmer Each input should show the correct state on the programmer 6 Check the controller s fault detection circuitry...

Page 23: ...r to Table 4 4 Troubleshooting Chart Operational faults such as an over temperature situa tion are cleared as soon as the operation is brought within range Non operational faults such as a throttle fa...

Page 24: ...ut short 1 4 0 0000 Sequencing fault SRO 2 1 00 0 Throttle wiper high 2 2 00 00 Emergency reverse circuit check fault BB wiring 2 3 00 000 High pedal disable fault HPD or expired timer 2 4 00 0000 Thr...

Page 25: ...ncy reverse wire or check wire open Re apply emergency reverse or cycle interlock 2 3 HPD 1 Improper sequence of KSI interlock and throttle inputs Follow proper sequence adjust throttle if necessary a...

Page 26: ...voltage falls below overvoltage cutoff point 4 3 THERMAL CUTBACK 1 Temperature 85 C or 25 C Clears when heatsink temperature returns to within acceptable range 2 Excessive load on vehicle 3 Improper m...

Page 27: ...901467 4 11 NOTES...

Page 28: ...4 12 901467 Figure 4 5 Wiring Diagram Sheet 1 R6490A...

Page 29: ...901467 4 13 Figure 4 5 Wiring Diagram Sheet 1 R6490B...

Page 30: ...4 14 901467 NOTES...

Page 31: ...on 1 with springs 3 on mounting bracket 5 and check for proper operation 10 Position button 1 with mounting bracket 5 in the control head 11 Install two screws 6 and two screw 7 12 Install the switch...

Page 32: ...wo washers 9 and two nuts 10 8 Position mounting bracket 8 in the control head and install two screws 11 9 Check that rollers on both switches 6 contact the surface of cam 4 but do not engage the swit...

Page 33: ...901467 5 3 Figure 5 2 Control Head and Steering Arm R6507...

Page 34: ...Position mounting bracket 13 in the control head and install two screws 11 9 Set an ohmmeter to the RX1K 1000 scale and connect across the potentiometer leads 10 Slowly press the control knob 18 in t...

Page 35: ...osition 1 Remove six screws 12 and cover 13 from the steering arm 7 2 Support steering arm 7 in the raised position 3 Remove clip 10 and pull pneumatic spring 9 from stud 11 4 Remove four screws 8 to...

Page 36: ...5 6 901467 Figure 5 4 Steering Control R6506...

Page 37: ...TION 7 2 Remove three screws 26 three washers 25 and brake assembly 24 6 1 2 Brake Installation 1 Position brake assembly 24 on the drive motor and secure with three screws 26 and three washers 25 2...

Page 38: ...6 2 901467 NOTES...

Page 39: ...e drive assembly 3 Pull the motor and brake wiring out of pivot tube 8 4 Remove four screws 7 and remove pivot tube 8 bearing 10 and mounting plates 11 and 12 from assembly 13 5 Remove the brake as de...

Page 40: ...7 2 901467 Figure 7 1 Drive Assembly R6510...

Page 41: ...901467 7 3 Figure 7 2 Fork Section R6519...

Page 42: ...eplace if necessary 5 Reassemble wheel in reverse of disassembly pro cedure 7 3 3 Load Wheel Installation 1 Position load wheel assembly 12 Figure 7 2 in wheel housing 14 2 Install pin 3 Figure 7 3 an...

Page 43: ...d pull out emergency disconnect switch 6 5 Remove pin 16 Figure 7 4 6 Remove shaft 15 and mounting bracket 17 or 21 7 Remove screw 18 and remove caster 20 from bracket 17 or 21 8 Remove nut 28 washer...

Page 44: ...forks to raise the load wheels off the floor Securely block the forks in the raised posi tion by positioning supports under both fork tips 5 Remove nut 10 Figure 7 2 screw 7 and roller 9 from the fork...

Page 45: ...and lower the truck to the ground 8 Turn on the keyswitch 4 Figure 12 7 and pull out switch 6 8 3 Power Section and Fork Section 8 3 1 Separating Power Section and Fork Section 1 Support entire truck...

Page 46: ...30 5 Remove hoist from fork frame 6 Figure 8 1 6 Install the lift cylinder as described in paragraph 9 2 4 7 Install covers 7 and 10 Figure 12 7 and secure with four screws 9 and two screws 8 8 Turn...

Page 47: ...901467 8 3 Figure 8 2 Frame R6516A...

Page 48: ...8 4 901467 NOTES...

Page 49: ...under the line or fitting before discon necting 4 Refer to Figure 9 2 and remove leaking line or fit ting and replace it with a new line or fitting 5 Remove breather 12 from the hydraulic reser voir...

Page 50: ...9 2 901467 Figure 9 2 Hydraulic System R6512...

Page 51: ...ads and spike suppressor from the solenoid located on valve 21 Figure 9 2 NOTE The reservoir and hose will be filled with hydraulic oil Place a container under the hose to catch any hydraulic oil 17 D...

Page 52: ...screws 6 Figure 12 9 and remove top plate 5 14 Ensure that hydraulic pressure has been relieved from the lift circuit Disconnect the hydraulic line from the lift cylinder 15 Disconnect hose 1 Figure 9...

Page 53: ...valve is functioning properly and does not need adjustment If pressure reading is not 2 600 psi proceed as follows to adjust relief valve CAUTION Do not set pressure too high or hydraulic system may...

Page 54: ...9 6 901467 NOTES...

Page 55: ...raise up cover 3 5 Tag and disconnect electrical leads from key switch 4 6 Remove the nut and remove key switch 4 7 Install new switch 4 and secure with supplied nut 8 Reconnect electrical leads as n...

Page 56: ...LACEMENT 1 Turn off the key switch 4 Figure 10 1 push in emergency disconnect switch 6 2 Remove four screws 9 two screws 8 and cov ers 7 and 10 3 Unscrew the red knob from emergency discon nect switch...

Page 57: ...901467 10 3 Figure 10 2 Steering Control R6506...

Page 58: ...to be taken There are no user serviceable parts inside the control ler No attempt should be made to open the controller Opening the controller may damage it and will void the warranty The controller...

Page 59: ...901467 10 5 Figure 10 4 Frame R6516A...

Page 60: ...n 3 Using an inline fuse holder fitted with a 10 amp fuse and alligator clips connect the controller s M and B terminals 4 Reconnect the battery and turn the key switch to the ON position Release the...

Page 61: ...indicator 5 and key switch 4 on top of the truck 7 Reconnect the wires to battery indicator 5 as noted during removal 8 Reconnect the wires to key switch 4 as noted during removal 9 Secure cover 3 wi...

Page 62: ...be cleaned at least once a month to assure proper cooling of motor Use an air hose to blow bust off of motor sur faces 1 Remove the drive assembly as described in para graph 7 2 1 2 Disassemble the d...

Page 63: ...901467 11 1 SECTION 11 OPTIONAL EQUIPMENT There is no optional equipment available at this time...

Page 64: ...11 2 901467 NOTES...

Page 65: ...901467 12 1 SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the PTE 30 Lift Truck...

Page 66: ...12 2 901467 Figure 12 1 Steering Control R6506...

Page 67: ...PAD 1 9 902308 SCREW 2 10 902304 RUBBER SLEEVE 1 11 902291 PIN SHAFT 1 12 902315 SCREW 2 13 902253 HANDLE SOCKET 1 14 902257 INNER COVER 1 15 NOT USED 2 16 902314 SCREW 2 17 902273 MOUNTING PLATE 1 18...

Page 68: ...12 4 901467 Figure 12 2 Steering Arm R6507...

Page 69: ...3 REF 2 902204 SCREW 2 3 902185 WASHER 2 4 902062 HANDLE 1 5 902127 SCREW 1 6 902366 SPRING PIN 1 7 902254 HANDLE TUBE 1 8 902277 SCREW 4 9 902294 PNEUMATIC SPRING 1 10 902401 CLIP 11 902402 STUD 12 9...

Page 70: ...902163 SPRING 4 4 902115 RUBBER BUMPER 1 5 902173 SWITCH BRACKET 1 6 902137 SCREW 2 7 902141 SCREW 2 8 902024 BUTTON LIFT 1 9 902164 SPRING 6 10 902023 BUTTON HORN 1 11 902137 SCREW 7 12 902045 COVER...

Page 71: ...SWITCH 2 7 902068 ISOLATE BLOCK 1 8 902078 MOUNTING BRACKET 1 9 902183 WASHER 4 10 902090 NUT 2 11 902141 SCREW 4 12 902059 GEAR 1 13 902079 MOUNTING BRACKET 1 14 902102 POTENTIOMETER 1 15 902172 SWI...

Page 72: ...02342 SEAT HOUSING 1 5 902287 O RING 1 6 902251 GROMMET 1 7 902307 SCREW 4 8 902293 PIVOT TUBE 1 9 902288 O RING 1 10 902218 BEARING 1 11 902275 MOUNTING PLATE 1 12 902274 MOUNTING PLATE 1 13 TRANSMIS...

Page 73: ...1 11 LINK 2 12 902089 NUT 8 13 902363 SPRING 4 14 902258 LEFT BRUSH SOCKET 2 15 902300 RIGHT BRUSH SOCKET 2 16 902224 BRUSH 4 17 902141 SCREW 4 18 902364 SPRING 1 19 INSULATING PLATE 4 20 SCREW 1 21...

Page 74: ...12 10 901467 Figure 12 7 Compartment R6521...

Page 75: ...QD 1 902323 SCREW 4 2 902400 SCREW 4 3 902268 MIDDLE PANEL 1 4 902070 KEY SWITCH 1 5 2001 116002 BATTERY INDICATOR 1 6 902239 EMERGENCY STOP BUTTON 1 7 902261 RIGHT PANEL 1 8 902314 SCREW 2 9 902320 S...

Page 76: ...O PART NO PART NAME NO REQD 1 056564 CAUTION DECAL 2 2 056617 FORWARD REVERSE DECAL 1 3 056499 NO RIDING DECAL 1 4 056613 OPER INSTR DECAL 1 5 061334 NAMEPLATE 1 6 066050 DRIVE SCREW 4 7 056632 BIG JO...

Page 77: ...901467 12 13 NOTES...

Page 78: ...12 14 901467 Figure 12 9 Frame R6516A...

Page 79: ...REW 2 15 902348 SHAFT 2 16 902368 SPRING PIN 2 17 902259 LEFT CASTER MOUNTING BRACKET 1 18 902334 SCREW 2 19 902213 BEARING 4 20 CASTER ASSEMBLY FIGURE 12 11 REF 21 902301 RIGHT CASTER MOUNTING BRACKE...

Page 80: ...12 16 901467 Figure 12 10 Fork Section R6519...

Page 81: ...40 ENTRY ROLLER 2 10 902277 NUT 2 11 902118 SCREW 2 12 WHEEL ASSY LOAD FIGURE 12 12 REF 13 902367 SPRING PIN 6 14 902399 WHEEL HOUSING 2 15 902343 SHAFT 2 16 902356 SPACER 4 17 902344 SHAFT 2 18 90221...

Page 82: ...12 18 901467 Figure 12 11 Caster Assembly R6518...

Page 83: ...EMBLY 2 1 902372 STEEL BALL 1 2 902354 SNAP RING 1 3 902279 NYLON SLEEVE 1 4 902280 NYLON SLEEVE 1 5 902398 WHEEL BRACKET 1 6 902336 SCREW 1 7 902395 WASHER 2 8 902219 BEARING 2 9 902396 WHEEL 1 10 90...

Page 84: ...12 12 Load Wheel Assembly R6520 INDEX NO PART NO PART NAME NO REQD 902265 LOAD WHEEL ASSEMBLY 2 1 902146 SEAL 2 2 902108 RING 2 3 902347 SHAFT 1 4 902211 BEARING 2 5 902264 LOAD WHEEL 1 INDEX NO PART...

Page 85: ...T NAME NO REQD 1 902226 BUSBAR 1 2 902056 FUSE 1 3 902238 ELECTRICAL PANEL 1 4 902225 BUSBAR 1 5 902037 CONTACT MAIN 2 6 902269 MOUNTING BRACKET 2 7 902042 CONTROLLER 1 8 902209 FUSE HOLDER 1 9 902037...

Page 86: ...12 22 901467 Figure 12 14 Hydraulic System R6512...

Page 87: ...GURE 12 15 REF 6 902380 TUBE ASSEMBLY 1 7 902246 GASKET 1 8 902323 SCREW 6 9 902233 COVER 1 10 902247 GASKET 1 11 902043 COVER 1 12 902405 BREATHER 1 13 NOT USED 14 902299 RESERVOIR 1 15 902332 SCREW...

Page 88: ...12 24 901467 Figure 12 15 Pump Motor Reservoir Assembly R6467...

Page 89: ...TOR RESERVOIR ASSEMBLY 1 1 902256 HYDRAULIC PUMP MOTOR 1 2 902216 BEARING 1 3 902221 BLOCK 1 4 902248 GASKET 1 5 902232 COUPLING 1 6 902297 PUMP ASSEMBLY 1 7 902129 SCREW 2 8 902318 SCREW 2 9 902391 W...

Page 90: ...12 26 901467 Figure 12 16 Cylinder Assembly R6467...

Page 91: ...901467 12 27 INDEX NO PART NO PART NAME NO REQD 902235 CYLINDER ASSEMBLY 1 1 902292 PISTON ROD 1 2 902237 DUST SEAL 1 3 902339 SEAL 1 4 902236 CYLINDER BODY 1 INDEX NO PART NO PART NAME NO REQD...

Page 92: ...12 28 901467 Figure 12 17 Valve Assembly R6513...

Page 93: ...283 O RING 1 11 COIL 1 12 902242 FITTING 1 13 902286 O RING 1 14 902241 FILTER 1 15 902389 WASHER 1 16 VALVE CAP 1 17 902284 O RING 1 18 902360 SPRING 1 19 902371 SPRING SOCKET 1 20 902374 STEEL BALL...

Page 94: ...12 30 901467 NOTES...

Page 95: ......

Page 96: ...Big Joe Manufacturing Company...

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