PTE 30 901467 - bigjoesupport.com

1 pte 30 SERIES. SELF-PROPELLED, PALLET. LIFT truck . Operation Maintenance Repair Parts List Big Joe Manufacturing Company Des Plaines, IL 60018 MANUAL NO. 901467 . 06/20/2017. WARNING. Do not operate this truck unless you have been autho- Always look in direction of travel. Keep a clear view, rized and trained to do so, and have read all warnings and when load interferes with visibility, travel with load and instructions in Operator's Manual and on this trailing. truck . Use special care when operating on ramps travel Do not operate this truck until you have checked its slowly, and do not angle or turn. Travel with lifting condition. Give special attention to tires, horn, battery, mechanism downhill. controller, lift system, brakes, steering mechanism, Do not handle loads which are higher than the load guards and safety devices. backrest or load backrest extension unless load is Operate truck only from designated operating position. secured so that no part of it could fall backward.

2 Do not carry passengers. Keep feet clear of truck and Before lifting, be sure load is centered, forks are com- wear foot protection. pletely under load, and load is as far back as possible Observe applicable traffic regulations. Yield right of against load backrest. way to pedestrians. Slow down and sound horn at When leaving truck , neutralize travel control, fully cross aisles and wherever vision is obstructed. lower lifting mechanism and set brake. When leaving truck unattended, also shut off power. Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surfaces that could cause truck to slide or overturn. Use special care when traveling without load as the risk of overturn may be greater. TABLE OF CONTENTS. Section Page Section Page 1 DESCRIPTION ..1-1 6 BRAKE SERVICING .. 6-1. 1-1. INTRODUCTION..1-1 6-1. BRAKES.. 6-1. 1-2. GENERAL BRAKE REMOVAL.. 6-1. 1-3. SAFETY FEATURES..1-2 BRAKE INSTALLATION.

3 6-1. 2 OPERATION ..2-1 7 TRANSMISSION, DRIVE WHEEL, LOAD. 2-1. GENERAL..2-1 WHEEL, BALANCE WHEEL AND ENTRY. 2-2. OPERATING PRECAUTIONS..2-1 ROLLER 7-1. 2-3. BEFORE 7-1. DRIVE WHEEL.. 7-1. 2-4. GENERAL CONTROL 7-2. DRIVE ASSEMBLY .. 7-1. 2-5. DRIVING AND STOPPING PROCEDURES..2-4 REMOVAL.. 7-1. 2-6. BELLY-BUTTON SWITCH..2-4 REPAIR .. 7-1. 2-7. STEERING ARM PNEUMATIC SPRING..2-5 INSTALLATION.. 7-1. 2-8. LIFT AND LOWER CONTROLS..2-5 7-3. LOAD WHEEL.. 7-1. 2-9. LOADING AND UNLOADING..2-5 REMOVAL .. 7-1. 2-10. PARKING..2-5 REPAIR .. 7-4. LOAD WHEEL 7-4. 3 PLANNED MAINTENANCE ..3-1 7-4. CASTERS .. 7-5. 3-1. GENERAL..3-1 REMOVAL .. 7-5. 3-2. MONTHLY AND QUARTERLY CHECKS..3-1 REPAIR .. 7-5. 3-3. BATTERY CARE..3-1 INSTALLATION .. 7-5. 3-4. CHARGING BATTERIES ..3-1 7-5. ENTRY ROLLERS .. 7-6. 3-5. LUBRICATION..3-2 ENTRY ROLLER 7-6. 4 TROUBLESHOOTING ..4-1 ENTRY ROLLER 7-6. 4-1. GENERAL ..4-1 8 ELEVATION SYSTEM SERVICING .. 8-1. 4-2. TRANSISTOR CONTROLLER 8-1.

4 8-1. TROUBLESHOOTING ..4-4 8-2. LIFT LINKAGE .. 8-1. FAULT DETECTION..4-4 REMOVAL .. 8-1. HAND HELD PROGRAMMER (OPTIONAL)..4-5 REASSEMBLY .. 8-1. FAULT RECORDING..4-5 8-3. POWER SECTION AND FORK 8-1. FAULT RECOVERY..4-5 SEPARATING POWER SECTION AND. GENERAL CHECKOUT..4-5 FORK SECTION.. 8-1. ADJUSTMENT ..4-6 FORK FRAME REPAIR.. 8-1. DIAGNOSTICS AND TROUBLESHOOTING..4-7 FRAME REPAIR.. 8-1. PROGRAMMER DIAGNOSTICS ..4-7 MATING POWER SECTION AND FORK. 5 STEERING ARM AND CONTROL HEAD SERIVCE ..5-1 8-1. 5-1. CONTROL HEAD ..5-1 9 HYDRAULIC SYSTEM 9-1. CONTROL HEAD REMOVAL..5-1 9-1. LINES AND FITTINGS .. 9-1. BELLY-BUTTON SWITCH REPLACEMENT..5-1 9-2. HYDRAULIC PUMP, MOTOR, AND. LIFT, LOWER AND HORN SWITCH RESERVOIR ASSY .. 9-3. REMOVAL .. 9-3. DIRECTIONAL SWITCH REMOVAL AND DISASSEMBLY AND REASSEMBLY .. 9-3. ADJUSTMENT..5-1 INSTALLATION .. 9-3. POTENTIOMETER REMOVAL TESTING LIFT CYLINDER .. 9-4. AND HYDRAULIC PRESSURE ADJUSTMENT .. 9-5. CONTROL HEAD INSTALLATION.

5 5-5. 5-2. STEERING ARM ..5-5 10 ELECTRICAL COMPONENTS .. 10-1. PNEUMATIC SPRING 10-1. KEY SWITCH 10-1. STEERING ARM 10-2. BATTERY INDICATOR 10-2. STEERING ARM 901467 i TABLE OF CONTENTS - Continued Section Page Section Page 10-3. EMERGENCY DISCONNECT SWITCH THE FAULT DETECTION CIRCUITRY10-6. REPLACEMENT.. 10-2 REMOVAL.. 10-6. 10-4. DEADMAN 10-2 DISASSEMBLY.. 10-6.. 10-2 INSTALLATION.. 10-7. 10-4 10-8. PUMP 10-8. 10-5. BATTERY DISCONNECT SWITCH.. 10-4 10-9. DRIVE MOTOR.. 10-8. 10-6. LIFT LIMIT SWITCH.. 10-4. 10-7. ELECTRICAL CONTROL PANEL .. 10-4 11 OPTIONAL EQUIPMENT ..11-1. 10-4 12 ILLUSTRATED PARTS BREAKDOWN .. 12-1.. 10-4. 10-6. LIST OF FIGURES. Figure Page Figure Page 1-1 NAME PLATE .. 1-1 9-1 COMPARTMENT .. 9-1. 1-2 PTE 45 LIFT truck .. 1-1 9-2 HYDRAULIC 9-2. 2-1 SAMPLE OF OPERATOR CHECK LIST .. 2-3 10-1 COMPARTMENT .. 10-1. 2-2 FORWARD/REVERSE CONTROL .. 2-4 10-2 STEERING CONTROL .. 10-3. 2-3 PUSHBUTTON SWITCHES .. 2-4 10-3 BRAKE ACTUATION.

6 10-4. 2-4 BRAKE ACTUATION .. 2-4 10-4 10-5. 2-5 BELLY-BUTTON SWITCH .. 2-5 10-5 ELECTRICAL PANEL .. 10-7. 3-1 LUBRICATION DIAGRAM .. 3-3 12-1 STEERING CONTROL .. 12-2. 4-1 STATUS 4-4 12-2 STEERING ARM .. 12-4. 4-2 ELECTRICAL PANEL PARTS .. 4-4 12-3 CONTROL 12-6. 4-3 CONTROLLER 4-5 12-4 CONTROL 12-7. 4-4 HAND HELD PROGRAMMER .. 4-6 12-5 DRIVE 12-8. 4-5 WIRING DIAGRAM (SHEET 1) .. 4-12 12-6 TRANSMISSION, BRAKE AND DRIVE. 5-1 CONTROL HEAD SWITCHES .. 5-2 MOTOR ASSY .. 12-9. 5-2 CONTROL HEAD AND STEERING ARM .. 5-3 12-7 COMPARTMENT .. 12-10. 5-3 DRIVE CONTROLS .. 5-4 12-8 12-12. 5-4 STEERING CONTROL .. 5-6 12-9 12-14. 6-1 TRANSMISSION, BRAKE AND DRIVE 12-10 FORK SECTION .. 12-16. MOTOR ASSEMBLY .. 6-1 12-11 CASTER ASSEMBLY .. 12-18. 7-1 DRIVE ASSEMBLY .. 7-2 12-12 LOAD WHEEL ASSEMBLY .. 12-20. 7-2 FORK SECTION .. 7-3 12-13 ELECTRICAL PANEL .. 12-21. 7-3 WHEEL 7-4 12-14 HYDRAULIC 12-22. 7-4 FRAME .. 7-5 12-15 PUMP, MOTOR & RESERVOIR ASSEMBLY.

7 12-24. 8-1 FORK SECTION .. 8-2 12-16 CYLINDER 12-26. 8-2 FRAME .. 8-3 12-17 VALVE ASSEMBLY .. 12-28. LIST OF TABLES. Table Page Table Page 2-1 OPERATOR 2-2 4-1 TROUBLESHOOTING 4-1. 3-1 MONTHLY AND QUARTERLY INSPECTION 4-2 ADJUSTMENT SETTINGS .. 4-7. AND SERVICE CHART .. 3-1 4-3 LED CODES .. 4-8. 3-2 RECOMMENDED LUBRICANTS .. 3-2 4-4 TROUBLESHOOTING 4-9. 3-3 LUBRICATION CHART .. 3-3. ii 901467 . SECTION 1. DESCRIPTION. 1-1. INTRODUCTION. forks raised of lowered. The lift truck must be pro- This publication describes the 24 volt transistor tected from the elements. pte 30 lift truck distributed by Big Joe Manufacturing The model number will be found on the name plate Company, Des Plaines, Illinois, 60018. Included are (Figure 1-1) along with the serial number, lifting capac- operating instructions, planned maintenance instruc- ity, and load center. Figure 1-2 shows the locations of tions, lubrication procedures, corrective maintenance the truck 's main components and controls.

8 Procedures and a complete parts list with part location illustrations. Users shall comply with all requirements indicated in applicable OSHA standards and current edition of Part II. By following these requirements and the recommendations contained in this manual, you will receive many years of dependable service from your Big Joe lift truck . 1-2. GENERAL DESCRIPTION. The self-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 control head. Stopping and turning is controlled by the steering arm. Lift and Lower is controlled by pushbuttons on the con- trol head. The battery powered lift truck is quite and without exhaust fumes. R6209. The reversible DC motor propels the lift truck in for- ward or reverse direction throughout the available Figure 1-1 Name Plate speed range. The pte 30 lift truck can be driven with R6525.

9 Figure 1-2. PTE 45 Lift truck 901467 1-1. 1-3. SAFETY FEATURES. Separately fused control circuits and power circuits. The pte 30 is designed and engineered to provide Readily accessible HORN button. maximum safety for operator and payload. Some of Slip-resistance hand to provide a firm hand hold for the safety features incorporated into the design are: operator. Dead-man brake to apply the brake and cut off drive Flow control valve regulates maximum lowering power when the steering arm is released. speed within prescribed limits. Belly-button switch to reverse truck should the oper- Relief valve maintains hydraulic pressure within pre- ator accidentally pin himself against a wall or scribed limits. obstruction when backing up in slow speed. High visibility color scheme of truck provides visual All control functions automatically return to OFF . alert of truck 's presence. when released. Battery Indicator Externally accessible emergency disconnect switch within operator's reach.

10 Casters 1-2 901467 . SECTION 2. OPERATION. 2-1. GENERAL. Do not overload truck . Check nameplate for load This section gives detailed operating instructions for weight and load center information. the pte 30 lift truck . The instructions are divided into Before lifting, be sure load is centered, forks are the various phases of operations, such as operating completely under load, and load is as far back as lift, driving, and stopping. Routine precautions are possible against load backrest. included for safe operation. Do not handle loads which are higher than the load backrest unless load is secured so that no part of it 2-2. OPERATING PRECAUTIONS. could fall backward. WARNING: Improper operation of the lift truck may When leaving truck , neutralize travel control. Fully result in operator injury, or load and/or lift lower lifting mechanism and set brake. When leaving truck damage. Observe the following truck unattended, turn off key switch and push in the precautions when operating the pte 30 emergency disconnect switch and remove key.