OPERATION • MAINTENANCE • REPAIR PARTS LIST PPT POWERED PALLET TRUCK PPT SERIES [PPT_40-0278] 2/2

TABLE OF CONTENTS
SECTION		PAGE	SECTION		PAGE
	PREPARATION FOR USE	1-1	III	MAINTENANCE AND MAINTENANCE PARTS (CONTINUED)
I	DESCRIPTION	1-2	3-5	Battery Care	3-2
1-1	Introduction	1-2	3-6	Lubrication	3-2
1-2	Description	1-2	3-7	Troubleshooting	3-4
1-3	General	1-2	3-8	Adjustment and Repair	3-8
1-4	Capabilities	1-2	3-9	Belly-Button Safety Switch Adjustment	3-8
1-5	Safety Features	1-2	3-10	Control Head Switch Replacement	3-8
1-6	Options	1-2	3-11	Steering Arm	3-10
II	OPERATION		3-12	Electrical Control Cable Replacement	3-12
2-1	General	2-1	3-13	Mechanical Brakes	3-13
2-2	Operating Precautions	2-1	3-14	Drive Motor Repair	3-17
2-3	Driving and Stopping	2-1	3-15	Chassis and Pivot Assemblies	3-17
2-4	General	2-1	3-16	Wheel Housings and Exit Rollers	3-28
2-5	Driving and Stopping Procedures	2-2	3-17	Saucer Assembly and Caster Replacement	3-29
2-6	Belly-Button Safety Guard	2-3	3-18	Load Wheel Replacement	3-30
2-7	Dynamic Brake	2-3	3-19	Transmission Repair	3-30
2-8	Steering Arm Return Spring	2-3	3-20	Drive Wheel Replacement	3-31
2-9	Various Stopping Methods	2-3	3-21	Hydraulic System Repair	3-34
2-10	Operating Lift	2-3	3-22	Hydraulic Pump-Motor-Reservoir Assembly	3-36
2-11	Loading and Unloading	2-3	3-23	Lift Cylinder Repair	3-38
2-12	Parking	2-3	3-24	Contactor Tip Replacement	3-40
III	MAINTENANCE AND MAINTENANCE PARTS		3-25	Speed Control Resistor Adjustment	3-40
3-1	General	3-1	3-26	Battery Connector Group Replacement	3-45
3-2	Part Number Identification	3-1	3-27	Metal Service Cover	3-45
3-3	Preventive Maintenance	3-1
3-4	Inspection and Service	3-1

LIST OF ILLUSTRATIONS
Figure		Page	Figure		Page
1-1	Powered Pallet Truck, Model PPT-40	1-2	3-20	Hydraulic System (Serial Number 81936 and Lower)	3-34
2-1	Steering Arm Controls	2-1	3-21	Hydraulic System (Serial Number 81937 and Higher)	3-35
2-2	Speed Control	2-1	3-22	Pump-Motor-Reservoir Assembly (Serial Numbers 81936 and Lower)	3-36
2-3	Mechanical Brake Application	2-2	3-23	Pump-Motor-Reservoir Assembly (Serial Numbers 81937 and Higher)	3-37
3-1	Lubrication Points	3-3	3-24	Lift Cylinder P/N 047552	3-38
3-2	Schematic Diagram	3-7	3-25	Lift Cylinder P/N 047564	3-39
3-3	Belly-Button Safety Switch Adjustment	3-8	3-26	70-Amp Contactor Wire Terminations	3-40
3-4	Control Head	3-9	3-27	70-Amp Contactor Tip Replacement	3-41
3-5	Pivot Tube and Steering Arm	3-11	3-28	Electrical Control Components and Battery Connector Group (Serial Number 67146 to 70874)	3-42
3-6	Electrical Control Cable Replacement	3-12	3-29	Contactor Panel (Serial Number 70875 and Higher)	3-43
3-7	Mechanical Brake Adjustment	3-13	3-30	Speed Control Resistor Assembly (Serial Number 70875 and Higher)	3-44
3-8	Drum Brake and Linkage	3-15	3-31	Battery Connector Group and Horn (Serial Number 70875 and Higher)	3-45
3-9	Disk Brake and Linkage	3-16	3-32	Metal Service Kit Bracket	3-46
3-10	Drive Motor	3-17	3-33	Bracket and Cover Drilling	3-46
3-11	Standard Chassis and Pivot Assembly (Eccentric Adjusted Push Rods)	3-22	3-34	Tapping Diagram	3-46
3-12	Standard Chassis and Pivot Assembly (Universal Push Rods)	3-24	3-35	Service Cover Assembly	3-46
3-13	Narrow Straddle Chassis and Pivot Assembly	3-26
3-14	Straddle and Pivot Blocks	3-28
3-15	Modification of Wheel Housing Casting	3-29
3-16	Special Length Push Rods	3-29
3-17	Caster Assembly	3-30
3-18	Tandem Load Wheels	3-31
3-19	Transmission and Drive Wheel	3-32
LIST OF TABLES
Table		Page	Table		Page
3-1	Inspection and Service Chart	3-1	3-3	Lubrication	3-3
3-2	Recommended Lubricants	3-2	3-4	Troubleshooting Chart	3-4

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
1	-----	Service Cover (Plastic service cover is no longer available, see paragraph 3-27 for metal cover conversion procedures and kit).	1		503429**	Pivot Arm, Lower Hand, Weldment	1
2	003108	Battery, 375A, 12 V	1	20	053103	Bushing	2
	003109	Battery, 450A, 12 V	1	21	052939	Bushing	1
	003124	Battery, 510A, 12V	1	22	503391	Spindle	1
3	503155	Carriage Assy, 27 in. Wide Backrest, 48 in. Fork Length	1	23	400458*	Shaft	2
	503495	Carriage Assy, 27 in. Wide Backrest, 42 in. Fork Length	1		296404**	Shaft (With 025712 Grease Fitting)	2
	503496	Carriage Assy, 27 in. Wide Backrest, 36 in. Fork Length	1	24	800167*	Pivot Arm, Lower Left Hand	1
4	294504	Shaft, ¾ x 8-5/8	1		503430**	Pivot Arm, Lower Left Hand	1
5	060974	Roll Pin, 3/16 x 1-1/4	2	25	053103	Bushing	2
6	501433	Wheel Assembly	4	26	052939	Bushing	1
	078255	Wheel	1	27	501485	Yoke (Also 31, fig. 3-5)	1
	051136	Bearing	2	28	052923	Bushing	2
7	312301	Axle	2	29	052926	Bushing	2
8	060976	Roll Pin, 3/16 x 1-1/2	7	30	501507	Saucer Assy	2
9	800081	Wheel Housing	2	31	077026	Flat Washer, ¾	6
10	025712	Grease Fitting	6	32	061719	Snap Ring	2
11	294505	Shaft	2	33	800078*	Pivot Arm Upper (Casting w/o Bushings)	1
12	060972	Roll Pin, 1/8 x 1	2		501432**	Pivot Arm Upper (Weldment with Bushings)	1
13	503289*	Push Rod, 36 in. Fork (8 in. Battery Box)	2	34	053103	Bushing	2
	503288*	Push Rod, 42 in. Fork (8 in. Battery Box)	2	35	052923	Bushing	2
	503214*	Push Rod, 48 in. Fork (8 in. Battery Box)	2	36	077082	Flat Washer, 13/16 I.D. x 1-1/2 O.D. x 9 Ga.	2
	501422**	Push Rod, 36 in. Fork (7-1/4 in.)	2	37	063869	Hex Head Cap Screw, ¾-10 x 2	2
	501421**	Push Rod, 42 in. Fork (7-1/4 in.)	2	38	296403	Shaft, 1 in. dia x 15-1/2	1
	501420**	Push Rod, 48 in. Fork (7-1/4 in.)	2	39	070476††	Round Head Screw, ¼-20 x ½	2
14	059437	Hex Nut, ½ x 13	2	40	277607	Steel Bushing	2
15	077412	Lock Washer, ½ External Tooth	2	41	313301	Roller	2
16	077213	Lock Washer, ½, Split	2	42	056475	Decal	1
17	064710	Hex Hd. Cap Screw, ½-13 x 3	2	43	056475	Maintenance Decal	1
18	400669	Eccentric Bushing	2	44	056499	No-Riding Decal	1
19	800168*	Pivot Arm, Lower Right Hand, Cast	1	45	401043†	Exit Roller	3
Note: For special length Push rods refer to Figure 3-16 for information on how to order replacement parts.				46	057182**	Stud (Plastic Service Cover)	2
†Standard on trucks serial number 82242 and higher. Older trucks may be retrofitted				47	057176**	Spring (Plastic Service Cover)	2
*Used on trucks serial number 74870 through 83306.				48	057177**	Nylon Wear Bushing (Plastic Service Cover)	2
**Used on trucks serial number 74869 and lower.				49	057178**	Retainer (Plastic Service Cover)	2
††Used with plastic service cover only (See paragraph 3-27 for metal cover attaching hardware).				50	057181**	Threaded Receptacle (Plastic Service Cover)	2
				51	250736**	Trim (Plastic Service Cover)	2
				52	071379**	Screw (Plastic Service Cover)	6

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
1	503731	Metal Service Cover	1	19	800168	Pivot Arm, Lower Right Hand Cast	1
2	---	Battery (See 2, fig. 3-11)	1	20	053103	Bushing	2
3	503155	Carriage Assy, 27 in. Wide Backrest, 48 in. Fork Length	1	21	064714	Hex Head Screw, ½-13 x 3	2
	503495	Carriage Assy, 27 in. Wide Backrest, 42 in. Fork Length	1	22	503391	Spindle	1
	503496	Carriage Assy, 27 in. Wide Backrest, 36 in. Fork Length	1	23	400458	Shaft	2
4	294504	Shaft, ¾ x 8-5/8	1	24	800167	Pivot Arm, Lower Left Hand	1
5	061025	Roll Pin, 5/16 x 1	2	25	053103	Bushing	2
6	501433	Wheel Assembly	4	26	052939	Bushing	1
	078255	Wheel	1	27	501485	Yoke (Also 31, fig. 3-5)	1
	051136	Bearing	2	28	052923	Bushing	2
7	312301	Axle	2	29	052926	Bushing	2
8	060976	Roll Pin, 3/16 x 1-1/2	7	30	501507	Saucer Assy	2
9	800081	Wheel Housing	2	31	077026	Flat Washer, ¾	6
10	025712	Grease Fitting	6	32	061719	Snap Ring	2
11	294505	Shaft	2	33	800078	Pivot Arm Upper (Casting w/o Bushings)	1
12	060972	Roll Pin, 1/8 x 1	2	34	053103	Bushing	2
	900697	Universal Push Rod Kit (48-in. straddles)	2	35	052923	Bushing	2
	900698	Universal Push Rod Kit (42-in. straddles)	2	36	077082	Flat Washer, 13/16 I.D. x 1-1/2 O.D. x 9 Ga.	2
	900699	Universal Push Rod Kit (36-in. straddles)	2	37	063869	Hex Head Cap Screw ¾-10 x 2	2
13	503720	Cross Head	1	38	296403	Shaft, 1 in. dia x 15-1/2	1
14	401080	Left Hand Hex Jam Nut, 1-8 UNC	1	39	063555	Hex Head Screw, 5/16-18 x 1	2
15	401078	Threaded Stud	1	40	277607	Steel Bushing	2
16	401079	Right Hand Hex Jam Nut, 1-8 UNC	1	41	313301	Roller	2
17	503719	Push Rod (48 in. straddles)	1	42	056475	Decal 0566631 door decal	1
	503732	Push Rod (42 in. straddles)	1	43	056564	Maintenance Decal caution	1
	503733	Push Rod (36 in. straddles)	1	44	056499	No-Riding Decal	1
18	401101	Bushing	1	45	401043	Exit Roller	4
				46	077217	Split Lock Washer, ½	2
				47	059437	Hex Nut, ½-13	2
				48	077210	Lock Washer, 5/16	2
				49	069705	Flat Head Screw, ½-13 x 1	2
				50	063705	Hex Head Screw, ½-13 x 1	1
					900928	Decal kit

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
1	294510	Shaft	2	25	800078*	Upper Pivot Arm (Cast New Style w/o Bushings)	1
2	060974	Roll Pin, 3/16 dia x 1-1/4	2		501432**	Upper Pivot Arm (Weldment Old Style with Bushings)	1
3	503582	Carriage Assembly, 27 in. Wide Backrest, 18-3/4 Fork O.D.	1	26	053103	Bushing	2
4	501692	Wheel Assembly	2	27	052923	Bushing	2
	078257	Wheel	1	28	077082	Flat Washer, 13/16 I.D. x 1-1/2 O.D. x 9 Ga.	2
	051136	Bearing	2	29	063869	Hex Hd Cap Screw, ¾-10 x 2	1
5	312304	Axle	2	30	296403	Shaft	1
6	060976	RollPin, 3/16 dia. X 1-1/2	7	31	277607	Bushing, Steel	2
7	800195	Wheel Housing (Cast, New Style)	2	32	503625*	Push Rod, Left Hand, 36 in. Forks (8 in. Battery Box) (18-3/4 in straddle)	1
	501924	Wheel Housing (Weldment, Old Style)	2		503623*	Push Rod, Left Hand, 42 in. Forks (8 in. Battery Box) (18-3/4 in straddle)	1
8	025712	Grease Fitting	10		503588*	Push Rod, Left Hand, 48 in. Forks (8 in. Battery Box) (18-3/4 in straddle)	1
9	800194	Pivot Arm Lower Right Hand (Cast, New Style)	1		503629**	Push Rod, Left Hand, 36 in. Forks (7-1/4 in. Battery Box) (18-3/4 in. straddle)	1
	502508**	Pivot Arm Lower Right Hand (Weldment, Old Style)	1		503627**	Push Rod, Left Hand, 42 in. Forks (7-1/4 in. Battery Box) (18-3/4 in. straddle)	1
10	052939*	Bushing (Used with Pivot Arm P/N 800194)	1		501927**	Push Rod, Left Hand, 48 in. Forks (7-1/4 in. Battery Box) (18-3/4 in. straddle)	1
	052923**	Bushing (Used with Pivot Arm P/N 502508)	1		503630	Push Rod, Left Hand, 36 in. Forks (7-1/4 in. Battery Box) (20 in. straddle)	1
11	052929**	Bushing (Used with Pivot Arm P/N 502508)	3		503628	Push Rod, Left Hand, 42 in. Forks (7-1/4 in. Battery Box) (20 in. straddle)	1
12	052923	Bushing	A/R		503926	Push Rod, Left Hand, 48 in. Forks (7-1/4 in. Battery Box) (20 in. straddle)	1
13	503391	Spindle	2	33	502116	Lug Weldment, Left Hand	1
14	296409	Shaft	2	34	502115	Lug Weldment, Right Hand	1
15	800193*	Pivot Arm, Lower Left Hand (Cast, New Style)	1	35	065620	Hex Head Cap Screw, ¾ x 2	2
	502509**	Pivot Arm, Lower Left Side (Weldment and Bushings)	1	36	063870	Hex Head Cap Screw, ¾ x 2-1/2	4
16	052939**	Bushing (Used with P/N 502509)	1	37	077217	Lock Washer, ¾	4
	052923	Bushing (Used with P/N 502509)	1	38	502331	Caster Assembly (See fig. 3-11)	REF
17	052929	Bushing	3	39	313307	Spacer	2
18	501928	Push Rod Yoke	1	40	---	Service Cover (Plastic Service Cover is no longer available, see paragraph 3-27 for conversion procedures and kit).	1
19	502502	Yoke (Also 31, fig. 3-5)	1	41	056475	Decal	1
20	052939	Bushing	2	42	056564	Maintenance Decal	1
21	294510	Shaft	2	43	056499	No Riding Decal	1
22	060972	Roll Pin, 3/16 dia x 1 in.	2	44	057182**	Stud (Plastic Service Cover)	2
23	503626*	Push Rod, Right Hand, 36 in. Forks (8 in. Battery Box) (18-3/4 in. straddle)	1	45	057176**	Spring (Plastic Service Cover)	2
	503624*	Push Rod, Right Hand, 42 in. Forks (8 in. Battery Box) (18-3/4 in. straddle)	1	46	057177**	Nylon Wear Bushing (Plastic Service Cover)	2
	503589*	Push Rod, Right Hand, 48 in. Forks (8 in. Battery Box) (18-3/4 in. straddle)	1	47	057178**	Retainer (Plastic Service Cover)	2
	503630**	Push Rod, Right Hand, 36 in. Forks (7-1/4 in. Battery Box) (18-3/4 in. straddle)	1	48	057181**	Threaded Receptacle (Plastic Service Cover)	2
	503628**	Push Rod, Right Hand, 42 in. Forks (7-1/4 in. Battery Box) (18-3/4 in. straddle)	1	49	250736**	Trim (Plastic Service Cover)	2
	501926**	Push Rod, Right Hand, 48 in. Forks (7-1/4 in. Battery Box) (18-3/4 in. straddle)	1	50	071379**	Screw (Plastic Service Cover)	6
	503629	Push Rod, Right Hand, 36 in. Forks (7-1/4 in. Battery Box) (20 in. straddle)	1	51	---††	Round Head, ¼-20 x 1/7	2
	503627	Push Rod, Right Hand, 42 in. Forks (7-1/4 in. Battery Box) (20 in. straddle)	1	52	---	Battery (See 2, fig. 3-11)	1
	503927	Push Rod, Right Hand, 48 in. Forks (7-1/4 in. Battery Box) (20 in. straddle)	1	53	400612	Spacer	A/R
24	313301	Exit Roller	2
††Used with plastic service cover. (See paragraph 3-27 for metal cover attaching hardware.
Note: For special length Pushrods, refer to Fig. 3-16 for information on ordering replacement parts.
*Used on trucks serial number 74870 and higher.
**Used on trucks serial number 74869 and lower.

3-16. WHEEL HOUSINGS AND EXIT ROLLERS
a. General.
Excessive wear of pivot blocks has occured on some standard chassis pallet trucks under severe operating conditions such as loading or unloading heavy loads from trucks on inclined ramps. Incorporation of new exit rollers between the standard wheel housing and pivot blocks will greatly reduce wear.
The standard wheel housings on trucks prior to serial number 82242 must be modified to accommodate the new exit rollers. Trucks with tandem load wheels cannot be modified. Procedures are provided for accomplishing this modification also for the replacement of the pivot blocks. It is suggested that the pivot blocks be replaced on any truck showing enlargement of the shaft hole in the pivot blocks.
b. Pivot Block Replacement.
The following parts are required when replacing pivot blocks:

PART NO.	PART NAME	QTY.
294504	Pivot Shaft	2
201127	Pivot Block	2
201128	Pivot Block	2
400065	Bar	4
061025	Roll Pin, 5/16 X 1	2
401043	Exit Rollers	4
---	Shaft ¾ in. dia X 36 in.	1

1.Refer to figure 3-14, and cut pivot blocks from both straddles with a torch then clean off slag to assure proper fit of new parts.
NOTE: One pivot block P/N 201127 and one pivot block 201128 are used in each straddle. The pivot blovk P/N 201127 is always mounted on the right side of the fork looking from the rear of the truck. The ¾-inch diameter by 36-inch long shaft is used to align the four pivot blocks.
2. Position the pivot blocks in the straddle using the 36-inch long shaft (see section A-A, figure 3-14) and adjust the position of the blocks for the 3-1/8 + 1/16-0 dimension shown in section A-A.
3. Weld pivot blocks in place.
4. Install the four bars P/N 400065 and weld as shown. Remove the 36-inch long shaft.
5. Modify the wheel hosuing and install in accordance with the following procedure.

Figure 3-14. Straddle and Pivot Blocks

c. Modifying and Installing Wheel Housing.
1. Disassemble the wheel housing.
2. Cut away the wheel housing casting as shown in figure 3-15, using a band saw and grinder. Grind surface “A” as smooth as possible. This surface will be in contact with the new exit rollers.
3. Reassemble the housing.
4. Attach assembled wheel housing to push rod.
5. Install wheel housing into straddle being sure that exit rollers are in place on wheel housing pivot shaft.
6. Secure pivot shaft to straddle with 5/16 roll pin.

Figure 3-15. Modification of Wheel Housing Casting

3-17. SAUCER ASSEMBLY AND CASTER REPLACEMENT.
1. Disconnect battery.
2. Securely block the load wheels to prevent the truck from moving.
3. Remove service cover.
4. Use a jack to raise the rear of the lift truck so that the drive wheel clears the ground.
5. Lower the truck on blocks, making certain the drive wheel os still clear of the ground.
6. Refer to the figure 3-11 or 3-12 as a guide in replacing the saucer assemblies (of standard-chassis trucks) when required.
7. Refer to figure 3-13 as a guide in replacing the casters (of narrow-straddle trucks) when required.
NOTE: The caster assembly illustrated in figure 3-17 is interchangeable with the older style caster assembly which is no longer available. If you are replacing an older style caster, it is recommended that both casters be replaced.

Figure 3-17. Caster Assembly

INDEX NO.	PART NO.	PART NAME	NO. REQD.
	502331	Caster Assy (38, fig. 3-13)	2
1	502323	Support	1
2	502330	Fork	1
3	400436	Shaft	1
4	075005	Spring	2
	078256	Wheel Assy	1
5	078230	Wheel	1
6	051130	Bearing	2
7	260407	Spacer	1
8	077023	Washer	2
9	270306	Pin, 1x 4	1
10	061725	Snap Ring	2
11	060973	Roll Pin, 3/16 x 1-1/8	1
12	061719	Snap Ring, 3/4	2
13	060971	Roll Pin, 3/16 x 7/8	1
14	077010	Washer	2
15	077015	Washer	2
16	077029	Washer	1
17	051136	Ball Bearing	1
18	061726	Snap Ring	1
19	053016	Bearing Thrust	1
20	800172	Washer	1

d

3-18. LOAD WHEEL REPLACEMENT.
The standard wheel assembly is illustrated in figures 3-11 and 3-12) and the tandem wheel assembly is illustrated in figure 3-18.
1. Disconnect battery.
2. Block the drive wheel to prevent the truck from moving.
3. Place a hydraulic jack under each straddle at reinforced section behind the load wheel under the pushrod. Raise the straddles until the load wheels clear the floor.
4. REmove roll pin securing wheel housing pivot shaft and pull shaft out of straddle.
5. Refer to exploded views to disassemble the wheel assembly.
3-19. Transmission Repair. (Figure 3-19)
To remove and disassemble the transmission (complete with drive wheel) proceed as follows:
1. Disconnect battery.
2. Securely block load wheels. REmove service cover.
3. Label all wire and cable leads connected to terminals mounted on the transmission; then disconnect the leads.
4. MAke sure the four cables to the drive motor are properly labeled A1, A2, F1, and F2; then disconnect the cables from the drive motor.
5. Disconnect the mechanical brake by removing clevis pin that secures the rod clevis to the lower level assembly.
6. Remove the drain plug (12) and drain the transmission oil.
7. Remove the two screws (39) and lock washers (29) which secure the motor to the transmission housing. LAy motor and attached brake parts aside until reassembly.
8. Disconnect brake rod from lower lever assembly.
9. Remove the four screws and washers that secure the transmission to the pivot tube assembly.
10. Remove the transmission and drive wheel from the truck by raising the rear of the lift truck with jacks or other suitable means and sliding the assembly out from under the truck.
11. Remove the four hex head cap screws (35) and lock washers (34), bearing cap (33) and gasket (32).
12. Remove bearing spacer (26).

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	501691	Tandem Load Wheels	2	8	077213	Lock Washer, ½	2
1	502592	Lift Arm, L.H.	1	9	059537	Jam Nut, ½-13	2
2	294504	Shaft	1	10	077033	Flat Washer, 1-inch	4
3	060976	Roll Pin	4	11	501813	Stop Block	1
	501692	Load Wheel Assy	2	12	240634	Shaft	1
4	078257	Wheel (Poly)	1	13	502593	Lift Arm, R.H.	1
5	051136	Ball Bearing	2	14	400697	Spacer	1
6	800157	Bushing	2	15	294508	Shaft	1
7	501690	Side Plate with Axle	1

13. Remove seven screws (30), two screws (38), and their lock washers (29); pry off transmission cover (28) and pull off cover gasket (27).
14. Remove ball bearing (25) and pinion spacer (24).
15. Remove intermediate gear (23) and square key (22).
16. Remove spur pinion (21).
17. Remove locknut (15) and lock washer (14).
18. Remove drive wheel and axle shaft (6) to free gear (13), roller bearing cones (8) and cups (9), and oil seal (7).
19. Remove ball bearing (20).
20. Refer to the disassembly instructions as a guide, and reverse the individual procedures of steps 19 through 1 to reassemble and reinstall the transmission.
21. Fill with transmission oil to fill plug.

3-20. DRIVE WHEEL REPLACEMENT.
1. Disconnect battery.
2. Securely block the load wheels to prevent the truck from moving.
3. Remove service cover.
4. Use a jack to raise the rear of the lift truck so that the drive wheel clears the ground.
5. Lower the truck on blocks, making certain the drive wheel is still clear of the grpound.
6. Remove the five retaining screws and lock washers that secure the drive wheel to the axle shaft and then pry off the wheel.
7. Reverse the above procedure to install new drive wheel.

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
1	501600	Drive Wheel, Rubber Lug	1	21	057211	Spur Pinion	1
2	077215	Lock Washer, 5/8	5	22	057902	Square Key, 5/16 x 1-3/8	1
3	064828	Hex Hd Cap Screw	5	23	057233	Intermediate Gear	1
4	016020	Drive Motor (See fig. 3-9)	1	24	074701	Pinion Spacer	1
	501596	Transmission Assy	1	25	051125	Bearing	1
5	042114	O-ring	1	26	074706	Bearing Spacer	1
6	050700	Axle Shaft	1	27	036105	Cover Gasket	1
7	073504	Oil Seal	1	28	800073	Transmission Cover	1
8	051112	Roller Bearing Cone	2	29	077211	Lock Washer, 3/8	11
9	051111	Roller Bearing Cup	2	30	064611	Hex Hd Cap Screw, 3/8-16 x 1-3/4	7
10	800072	Housing	1	31	026304	Fill Plug, 3/8 Pipe Thread	1
11	060585	Dowel Pin	3	32	036106	Bearing Cap Gasket	1
12	026302	Drain Plug	1	33	051159	Bearing Cap	1
13	057210	Gear	1	34	077210	Lock Washer, 5/16	4
14	077600	Lock Washer	1	35	063555	Hex Hd Cap Screw, 5/16-18 x 1	4
15	059680	Locknut	1	36	026704	Street Elbow	1
16	074702	Motor Pinion Spacer	1	37	076701	Vent	1
17	057234	Motor Pinion Spur	1	38	064615	Hex Hd Cap Screw, 3/8-16 x 2-1/4	2
18	059745	Hex Nut, 5/8-18	1	39	064620	Hex Hd Cap Screw, 3/8-16 x 3-3/4	2
19	060428	Cotter Pin	1
20	051126	Ball Bearing	1

3-21. HYDRAULIC SYSTEM REPAIR (FIGURE 3-20 OR 3-21)
Figure 3-20 illustrates the complete hydraulic systems for trucks with serial number 81936 and lower. The hydraulic system for newer trucks is shown in figure 3-21. The pump-motor-reservoir assembly (1) and the lift cylinder are repairable.

Refer to paragraphs 3-22 and 3-23 for instructions for removing, disassembling, and repairing these assemblies.
WARNING: Before disconnecting hydraulic lines, make certain that the system is not under pressure.

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
1	016575	Pump-Motor-Reservoir Assy (See fig. 3-22)	1	9	026135	Nipple	1
2	025532	90° Adapter	1	10	047552	Lift Cylinder (See fig. 3-24)	1
3	025521	Elbow	1	11	025501	90° Adapter	1
4	026110	Nipple	1	12	282515	Vinyl Tube	1
5	026708	Street Elbow	3	13	161295†	Bracket	1
6	501498	Hose Assy	1	14	064607†	Hex Hd Cap Screw, 3/8-16 x 1-1/4	2
7	025313	Adapter	1	15	077211††	Lock Washer, 3/8	2
8	047110	Flow Regulator	1	16	063603	Hex Hd Cap Screw, 3/8-16 x 3/4	2
†Used on trucks serial numbers 74870 to 81937.				††Four used on trucks serial number 74869 and lower.

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	016575	Pump-Motor-Reservoir Assy (1, fig. 3-20)	REF		900282	Pump Assy with Solenoid Cartridge	1
	900271	Pump Motor	1	12	900281	Pump Assy	1
1	009305	Commutator End Head	1	13	900272	Solenoid Cartridge	1
2	003501	Brush Spring & Holder Package	1	14	900273	Solenoid Strainer	1
3	003702	Brush Set	1	15	900276	O-ring	1
4	900172	Thrust Washer	1	16	900270	Strainer	1
5	900171	Field Coil Package	1	17	900268	Reservoir	1
6	900170	Thru Bolt Package	1	18	026704	Street Elbow	1
7	900173	Terminal Stud Package	1	19	029102	Breather (Supplied with pump)	1
8	900280	Armature	1	20	900279	Magnet	1
9	051168	Drive End Bearing	1	21A	900266	Solenoid Start Switch (Early Models)	1
10	900275	Coupling	1	21B	020419	Solenoid Start Switch (Late Models)	1
11	900274	Oil Seal	1

3-22. HYDRAULIC PUMPUMP-MOTOR-RESERVOIR ASSEMBLY. (Figures 3-22 and 3-23)
The hydraulic pump-motor-reservoir assembly may be repaired. The motor can be rebuilt, but a defective pump has to be replaced as complete unit. Refer to figure 3-22 for breakdown of motor. Proceed as follows to remove and disassemble hydraulic pump-motor-reservoir assembly:
1. Lower lift carriage fully and disconnect battery.
WARNING: Before disconnecting hydraulic lines, make certain that the system is not under pressure.
2. Remove service cover.
3. Unscrew breather cap and drain the hydraulic oil from the reservoir into a clean bucket or suitable container.

NOTE: A few feet of ½-inch hose will facilitate draining oil from the reservoir.
4. Remove hydraulic lines from pump and electric wires from motor, labeling each wire to assure proper reassembly.
5. Remove assembly from truck by removing the screws and lock washers that secure it and its mounting bracket to the left vertical bar of the carriage assembly.
6. Disassemble using figure 3-22 as a guide for pump-motor-reservoir assembly 016575 and 3-23 for assembly 016580.
NOTE: Before reassembling pump-motor-reservoir assembly, it is recommended that all O-rings and gaskets be replaced.

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	016575	Pump-Motor-Reservoir Assy (1, fig. 3-20)	REF		900282	Pump Assy with Solenoid Cartridge	1
	900271	Pump Motor	1	12	900281	Pump Assy	1
1	009305	Commutator End Head	1	13	900272	Solenoid Cartridge	1
2	003501	Brush Spring & Holder Package	1	14	900273	Solenoid Strainer	1
3	003702	Brush Set	1	15	900276	O-ring	1
4	900172	Thrust Washer	1	16	900270	Strainer	1
5	900171	Field Coil Package	1	17	900268	Reservoir	1
6	900170	Thru Bolt Package	1	18	026704	Street Elbow	1
7	900173	Terminal Stud Package	1	19	029102	Breather (Supplied with pump)	1
8	900280	Armature	1	20	900279	Magnet	1
9	051168	Drive End Bearing	1	21A	900266	Solenoid Start Switch (Early models)	1
10	900275	Coupling	1	21B	020419	Solenoid Start Switch (Late Models)	1
11	900274	Oil Seal	1

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	016580	Pump-Motor-Reservoir Assy (1, fig. 3-22)	1	17		Return Tube	1
1	900271	Pump-Motor (See fig. 3-22, items 1 through 9)	REF	18		Push On Ring	1
	900682	Pump Seal Kit	1	19		Washer	1
2		Oil Seal	1	20		O-Ring	1
3		O-Ring	1		900688	Flow Regulator Kit	1
4		O-Ring	2	21		Flow Control Spool	1
5		Gasket	1	22		Spring	1
	900683	Adapter Kit	1		900692	Relief Valve Kit	1
6		Adapter	1	23		Adjusting Screw	1
7		Retainer	1	24		O-Ring	1
8		Screw	2	25		Hex Cap Nut	1
9		O-Ring	1	26		Gasket	1
	900684	Pump Kit	1	27		Spring	1
4		O-Ring	1	28		Plunger	1
5		Gasket	2	29		Relief Valve Seat	1
10		Pump	1	30		O-Ring (Relief Valve Seat)	1
11		Screw	4	31	900693	Reservoir	1
12		Coupling	1	32	900694	Hex Hd Screw, Thread Forming, ¼-20 x 3/8	6
	900685	By-Pass Tube Assy	1	33	900279	Magnet	1
13		Return Tube	1	34	026703	Street Elbow	1
14		Push On Ring	1	35	900270	Strainer (Reservoir)	1
15		Shim	1	36	026129	3/8 Pipe Nipple, 5 in. Long (Inlet)	1
16		O-Ring	1	37	900700	12-volt Solenoid Release Valve	1
	900686	Return Tube Assy	1	38	900273	Solenoid Strainer	1
				39	900695	Check Valve Assy	1

3-23. LIFT CYLINDER REPAIR
Two different lift cylinders are used on the PPT-40. When disassembling lift cylinder, be sure to refer to the correct procedure. The cylinder can easily be identified by the inlet and outlet parts. On lift cylinder P/N 047552 (figure 3-24) the parts are flush with the barrel assembly. On lift cylinder P/N 047654 (figure 3-25) the parts protrude from the barrel assembly. Refer to paragraph 3-23b to disassemble lift cylinder P/N 047552, and to paragraph 3-23c for lift cylinder P/N 047654.
a. Removal from Truck.
1. Fully lower the lift carriage.
2. Disconect battery.
3. Remove service cover.
WARNING: Before disconnecting any hydraulic lines, make certain the system is not under pressure.
4. Disconnect overflow hose from top of lift cylinder.

5. Remove snap rings (18).
6. Remove top shaft (16) and bottom shaft (17); then withdraw lift cylinder down and away from the lift carriage.
b. Disassembly of Lift Cylinder P/N 047552 (Figure 3-24)
1. Secure lift cylinder in a vise; then remove lock wire (4) and spacer (5).
2. Remove retaining ring (6).
3. Pull out eye (1), withdrawing rod (9), cylinder head (7), and attached parts.
CAUTION: Use proper pipe-clamp vise with non-marring jaws to prevent damaging the finish on the rod.
4. Secure rod in vise; then remove retaining ring (13) and packing (12).
5. Remove screw (14), piston (11), and O-ring (10).
6. Loosen nut (2) and remove it and eye (1) from rod (9).

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	047552	Lift Cylinder (10, fig. 3-13)	REF	10	900256*	Rod O-ring	1
1	900264	Eye	1	11	900255	Piston	1
2	900263	Jam Nut, ¾-10	1	12	900254*	Packing	1
3	900262*	Wiper	1	13	900253*	Packing Retaining Ring	1
4	900265*	Lock Wire	1	14	900252	Hex Head Cap Screw	1
5	900261*	Spacer	1	15	900251	Barrel Assembly	1
6	900260*	Head Retaining Ring	1	16	294519	Shaft	2
7	900258	Head	1	17	061719	Snap Ring	4
8	900259*	Head O-ring	1	*Included in 900547 repacking kit.
9	900257	Rod	1	*Included in 900547 repacking kit.

7. Withdraw cylinder head (7) from rod.
8. Remove O-ring (8) and wiper (3).
NOTE: Before reassembling the hydraulic lift cylinder, it is recommended that the O-rings (8, 10) and packing (12) be replaced.
c. Disassembly of Lift Cylinder P/N 047564 (Figure 3-25)
1. Secure lift cylinder barrel in a vise.

2. Locate hole in side of lift cylinder where lock wire (6) is visible.
3. Rotate gland (5) clockwise and lock wire (6) should exit through hole. Remove lock wire.
4. Pull up on eye (1) to extract rod (8) piston (10) and attching parts from barrel (15).
CAUTION: Use proper pipe clamp vise with non-maring jaws to prevent damaging the finish of the rod.

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	047564	Lift Cylinder	REF	10	900681	Piston	1
1	900576	Eye	1	11	900674*	O-ring Piston	1
2	900577	Jam Nut, ¾-10	1	12	900675*	Piston Seal	1
3	900578*	Wiper	1	13	900676*	Wear Strip	1
4	900579*	Seal	1	14	900587	Hex Nut, Self Locking	1
5	900680	Gland	1	15	900678	Barrel Assembly	1
6	900677*	Lock Wire	1	16	294519	Shaft	2
7	900672*	Gland Static	1	17	061719	Snap Ring	4
8	900679	Rod	1	*Part of cylinder rebuilding kit P/N 900671
9	900673*	Rod Static Seal	1	*Part of cylinder rebuilding kit P/N 900671

5. Secure rod in vise; then remove nut (14), piston (10) and rod static seal (9).
6. Remove nut (2) and eye (1) from rod (8).
7. Withdraw gland (5) from rod.
NOTE: Use parts in rebuilding kitP/N 900671 to replace items 3, 4, 6, 7, 9, 11, 12 and 13 before reassembly.
8. Reassemble in reverse order of disassembly. Insert lock wire (6) through slot in side of barrel and rotate gland (5) counterclockwise until lock wire is wrapped into barrel to lock assembly together.
3-24. Contactor Tip Replacement. (Figure 3-26 through 3-29)
The contactor tips (forward and reverse) should be replaced if they are badly pitted or worn. It is advisable to replace the movable and stationary contact tips at the same time. (Refer to Figure 3-27 part number identification of replacement parts). Proceed as follows:
1. Disconnect battery.
2. If they are not clearly marked, label the wires connected to the contactor tips (see figure 3-26).
3. Refer to figure 3-27. Replace the movable contactor tips and reinstall hardware and insulators as illustrated. (Kit No. 900140 is available for replacement hardware.)
4. Remove hex head screws that secure wires, jumpers, and stationary contacts. Replace stationary contacts

and reinstall jumpers. Refer to figure 3-26 to reconnect wires. Reinstall screws.
5. Check that contact gap is at least 3/16 inch at contact tip center.
6. Connect battery.
3-25. Speed Control Resistor Adjustment. (Figures 3-28 and 3-30)
Each half of the speed control resistor is switched in series with the drive motor and the negative side of the battery during one or more steps of acceleration. Moving the terminals on the speed control resistor changes the resistance in the circuit, which changes the rate of travel of the truck in foirst and second speed.
NOTE: The speed control resistor is adjusted at the factory for a reasonable set of speed increments. Do not alter the setting without a good reason.
1. Referring to the schematic diagram, locate the end terminal that supplies current to the speed control resistor in first speed.
2. Move this terminal awayfrom the center terminal, lengthening the effective resistance strip, to decrease the rate of travel in first speed.
3. Move both the terminals away from the center terminal to decrease the rate of travel in first and second speeds.

INDEX NO.	PART NO.	PART NAME	NO. REQD.
	005604	Contactor Assembly 70-Amp (12V)	1
1	005610	Contactor Bar Assy L.H.	1
2	005609	Contactor Bar Assy R.H.	1
	900140	Plunger Tip Assy	1
3	NP	Nut	1
4	NP	Lock Washer	1
5	NP	Flat Washer	1
6	NP	Insulator	1
7	NP	Insulator	1
8	NP	Spring	1
9	005113	Coil (12V)	1
10	017821	Plunger	1
11	062921	Hex Screw ¼-20 x ½	4
12	077219	Lock Washer, ¼	4
13	005608	Stationary Contact Tip	4

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	502382	Contactor Panel Assy	1	9	020419	Solenoid	2
1	502358	Enclosure	1		501607	Battery Connector Group	1
2	250743	Cover (not shown)	1	10	005410	Battery Connector	1
3	005604	Contactor Assy	1	11	800069	Fuse Block (one stud)	1
4	008904	Fuse Receptacle	1	12	008902	Fuse Block (two studs)	1
5	008910	Fuse, 15-A	1	13	008906	Fuse, 300-A	1
	502370	Resistor Assy	1	14	012707	Time Delay Relay, One Second (optional) (not shown)	1
6	018907	Dynamic Brake Resistor	1	15	021708	Time Delay Relay, Two Second (optional) (not shown)	1
7	020719	Dynamic Brake Solenoid	1
8	018900	Speed Control Resistor	1

INDEX NO.	PART NO.	PART NAME	NO. REQD.
	502382	Contactor Panel Assy	1
1	502358	Enclosure	1
2	306201	Dust Cover	1
3	008910	Fuse, 15-Amp	1
4	008904	Fuse Block	1
5	068230	Round Hd Screw, 6-32 x 3/8	1
6	059412	Hex Nut, 6-32	1
7	020719	Dynamic Brake Solenoid	1
8	059416	Hex Nut, ¼-20	2
9	077011	Washer, 5/15	2
10	250743	Cover	1
11	071379	Screw	2
12	005604	Contactor Assy	1
13	071379	Screw	4
14	018907	Dynamic Brake Resistor, with Mounting Hardware	1
15	068407	Lock Washer, No. 10	2
16	077208	Hex Nut, 10-32	4
17	059416	Hex Nut, ¼-32	2
18	059421	Hex Nut, ¼-20	2
19	077209	Lock Washer, 1/4	2

INDEX NO.	PART NO.	PART NAME	NO. REQD.
	502370	Resistor Assembly	1
1	018900	Speed Control Resistor	1
2	250731	Speed Control Bracket	1
3	101284	Bracket	1
4	070476	Round Hd Phillips Screw, ¼-20 x ½	4
5	077209	Lock Washer, ¼	4
6	305407	Bus Bar	1
7	059427	Hex Nut, 5/16-18	6
8	077210	Lock Washer, 5/16	6
9	020419	Solenoid	2
10	070476	Round Hd Phillips Screw, ¼-20 x ½	4
11	077209	Lock Washer, ¼	4
12	059421	Hex Nut, ¼-20	4
13	021221	Terminal Assy with Screw	3
14	068475	Round Hd Screw, ¼-20 x 3/8	3
15	077209	Lock Washer, ¼	3
16	059813	Square Nut, ¼-20	3

3-26. Battery Connector Group Replacement. (Figure 3-31)
The battery connector group makes it possible to quickly disconnect the entire electrical circuitry from the battery by means of the quick-disconnect plug. Refer to figures 3-28 or 3-31 for location and replacement of parts in this group.
3-27. METAL SERVICE COVER
a. This paragraph covers modification procedures to adapt pallet trucks (serial number 83008 and lower)

to accommodate the new metal service cover (503731).
All parts necessary for the modification are contained in kit number 900696.
The plastic service cover (056556) will not be available as a replacement part.
b. Modification Procedure
In order to fit the metal service cover to trucks supplied with the plastic cover, refer to figures 3-32 through 3-35 and follow this procedure:
1. Remove plastic service cover.

INDEX NO.	PART NO.	PART NAME	NO. REQD.	INDEX NO.	PART NO.	PART NAME	NO. REQD.
	501607	Battery Connector Group	1	8	009600	Horn	1
1	005401	Battery Connector	1	9	068480	Round Hd Screw, ¼-28 x 1	2
2	800069	Fuse Block (One stud)	1	10	077209	Lock Washer, ¼	2
3	008902	Fuse Block (Two studs)	1	11	077209	Lock Washer, ¼	2
4	008906	Fuse, 300-A	1	12	059421	Hex Nut, ¼-20	2
5	111765	Bracket	1	13	077105	Washer	7
6	069484	Flat Hd Phillips Screw, ¼-20 x 2	2	14	059425	Hex Nut	8
7	070476	Round Hd Phillips Screw, ¼-20 x 1/2	2	15	069478	Flat Hd Phillips Screw, ¼-20 x 3/4	1
				16	056507	LAbel	1

NOTE: Cover brackets (401106) are not used on narrow-straddle models. Proceed to step 3 if fitting metal cover to narrow straddle truck.
2. Refer to figure 3-32. Place a cover bracket on a side brace. Be certain that outside of bracket is flush with inside of bumper, and mark location. Either weld bracket to side brace, or drill 5/8-inch hole in side brace and attach bracket with ½-13 x 1 hex head screw, lock washer, and nut. Attach second cover bracket to other side brace.

Figure 3-32. Metal Service Kit Bracket

3. Place metal cover onto truck. Since the cover will be used as a template for drilling mounting holes, be certain that the cover is straight, that tab at bottom is tight against inside of bumper, and that holes at the side of cover line up with cover brackets (side braces on narrow-straddle trucks).
4. Using metal cover as a template, drill two ¼-inch holes at bottom as shown in figure 3-33. Then at the rear of

Figure 3-33. Bracket and Cover Drilling

bumper, measure two inches down from cover and drill 27/64-inch hole through bumper and tab.
5. Remove cover and tap hole in tab with ½-13 tap. See figure 3-34.
6. Enlarge hole in bumper to 5/8 inch. Tap holes in cover brackets (side braces on narrow-straddle trucks) with ½-13 tap. Tap holes at top with 5/16-18 tap. (Figure 3-34)

3-34. Tapping Diagram

7. Place cover on truck and attach with hardware as shown in figure 3-35.
8. Apply big Joe Decal to service cover.

3-35. Service Cover Assembly

PART NO.	PART NAME	NO. REQD.
900697	Metal Cover Service Kit	1
503731	Metal Cover	1
401106	Cover Bracket	2
---	½-13 x 1 Hex Head Screw	3
---	½-13 x 1 Flat Head Screw	2
---	½ Lock Washer	2
---	½-13 Hex Nut	2
---	5/16-18 x 1 Hex Head Screw	2
---	5/16 Lock Washer	2
056475	Decal	1

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