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DP SERVICE INSTRUCTIONS SELF PROPELLED STRADDLE LIFT TRUCK MODELS PD20-30 SERIES [PD20-30]

Complete guide for operating and servicing self-propelled straddle lift trucks models PD20-30 series.

Updated at February 20th, 2025

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SERVICE INSTRUCTIONS
SELF PROPELLED STRADDLE LIFT TRUCK
MODELS PD20-30 SERIES

INTRODUCTION

Your Big Joe Model PD20 Series self-propelled, straddle lift truck is produced under the finest quality controlled production methods. It is designed to give the maximum in service and performance. Study this instruction manual carefully to take full advantage of its many features.
In the table of contents you will find the page number for operation, maintenance, service, and repair parts information for the equipment. Following the recommended practices contained in this instruction manual will help your equipment give you many years of dependable service.

CONTENTS

General Information	1	Contactor Tip Replacement	10
Truck Identification	2	Resistor-Adjusting Speed	10
Preparation for Use	3	Hydraulic Pressure Adjustment	10
Operating Instructions	3	Flow Control Valve Adjustment	10
Operating Precautions	3	Electrical Circuit	10-11
Battery Care	4	Base and Frame Assemblies	12-13
Charging the Battery	4	Steering Arm & Pivot Assembly	14-15
Maintenance Inspection & Service	4	Transmission, Exploded View	16
Inspection and Service Chart	5	Transmission, Complete	17
Lubrication Instructions	6	Drive Motor, Exploded View	18
Mechanical Brake Adjustment	7	Hydraulic Pump & Motor	19
Drive Wheel Replacement	7	Cylinder Assembly	20
Steering Arm Spring Tension Adjustment	7	Hydraulic System	21
Electrical Control Cable	7-8	Throttle Valve Assembly	22
Transmission Maintenance	8	Brake Assembly	23
Throttle Valve Adjustment	8-9-10	Electrical Wiring Diagram	24
Chain Length Adjustment	10	Electrical Panel	25

INFORMATION AND SPECIFICATIONS

The Model PD20, self-propelled, straddle lift truck is designed to provide an efficient mechanical means for lifting, moving, and stacking materials. A heavy-duty, 12-volt battery supplies power to the electric drive motor and to the hydraulic pump motor. The truck lifts and moves heavy objects of various sizes and shapes through simple lever and push-button controls. A high torque, heavy duty, reversible electric motor bolted directly to the transmission drives a 10" x 5" rubber tire, lug type wheel. Positive uniform traction of this drive wheel is assured at all times by a springing arrangement which maintains constant traction when going over obstacles, depressions, and up and over ramps. The drive wheel is also the steering wheel. It is turned by rotating the steering arm when in a lowered position of 15 degrees or more which pivots the motor, transmission, and drive wheel to provide 200 degrees of steering arc.
Movement of the lift truck is accomplished by a butterfly control (located inside the handle guard on the steering arm) to allow finger-tip control of three speeds, forward or reverse. A push-button electric brake control providing dynamic braking on the motor is located in the center of the butterfly control. This is controlled by the operator regardless of the position of the steering arm up to the point where the deadman cut-off switch is set. At this point the mechanical brake takes over. The spring handle guard covering the speed and brake controls is secured at one end only. Pressure exerted against this guard actuates a switch, which reverses the direction of travel forward as a safety precaution. A mechanical parking brake, mounted on the drive motor sets automatically when the spring-loaded steering arm is released and returns to the upright position. This action also cuts off electrical power to the drive motor.
Hydraulic pressure for operation of the lift mechanism is supplied by a large, heavy-duty hydraulic pump and motor assembly. The pump provides excellent volumetric efficiency over a wide pressure range. The lift control is located on the right side of the mast for each reach. Positive controls allow smooth and accurate stops for ‘inching’ and ‘spotting’ of loads. The hydraulic cylinder located in the mast provides the lift by raising the mast, and the fork assembly rides by means of two heavy-duty link chains. The industrial type, 12-volt battery is maintained at full charge by means of the automatic 50-ampere battery charger supplied.

GUARANTEE

1. Big Joe Manufacturing Company guarantees its equipment to the original purchaser to be free from defects in material and workmanship for a period of 90 days from the date of sale.
2. The manufacturer's warranty on all parts purchased by Big Joe Manufacturing Company and included in our equipment is extended to the purchaser.
3. All Big Joe parts on which claims are made shall upon authorization by the company be returned for inspection, transportation charges PREPAID. No claim will be allowed which, in the opinion of the company, has resulted from excessive overload or abuses or accident. The Guarantee does not cover pumps or parts worn out in service. THis Guarantee is VOID if anything by Big Joe Hydraulic oil is used in this unit. DO NOT USE BRAKE FLUID. Replaced parts will be shipped F.O.B. Factory.
4. The company will not accept bills for service, labor or other expenses that has not been previously approved and authorized.
5. No responsibility for contingent liability through failure of any parts of the machine will be assumed by the company.
6. Big Joe hydraulic lift trucks are designed for a long and useful life with minimum maintenance expense if (1) they are not overloaded, (2) otherwise abused and (3) they are used and maintained in accordance with recommended operating and lubricating instructions.

TRUCK IDENTIFICATION

A.Steering Pivot Offset	K. Identification	T. Drive Wheel
B. Steering Arm	L. Forks	U. Transmission and Drive Motor
C. Reverse Speed Control	M. Lift Control Handle	V. Hydraulic Oil Reservoir
D. Brake Button	N. Throttle Valve	W. Hydraulic Motor Solenoid
E. Forward Speed Control	O. Battery	X. Traction Spring
F. Hydraulic Cylinder	P. Battery Cover	Y. Electrical Panel
G. Lift Chains	Q. Hydraulic Motor and Pump	Z. Electrical Panel Door
H. Inner Mast	R. Front Wheels
J. Lift Carriage	S. Rear Casters

OPERATING INSTRUCTIONS

PREPARATION FOR USE
Remove the cardboard packing from the lift truck. Remove and unpack the battery charger. Cut the bands securing the straddle frame to the skid and remove the lift truck from the skid. Open the battery compartment cover and remove the battery cable. Plug the quick disconnect of the battery cable into its mating connector at the ledt side of the mast.
OPERATING INSTRUCTIONS
Lower the spring-loaded steering arm (B, fig. 1) from the vertical position. (When the steering arm is in the vertical position, the parking brake is engaged.) For forward movement of the lift truck, depress the forward (front) speed control (E, fig. 1). Three forward and three reverse speeds are available depending upon how far down the control lever is depressed. For reverse movement, depress the reverse (rear) speed control (C).
NOTE: See information under Electrical Circuit (page 10) on how the electrical circuit functions. This information will help you understand the operation of the truck through its various speeds, forward and reverse.
To stop the truck, three different methods of braking can be used. The dynamic push button brake (D, fig. 1) located between the forward and reverse speed controls is pre-set for a definite braking action and should be used for most general braking requirements of the machine. This brake is factory set to stop the machine as quickly as possible withput jarring the load on the forks.
At times when more braking is necessary, the motor can be reversed in the first speed in the opposite direction of travel without harm to the motor or transmission.
The mechanical brake can also be used by raising the handle up to set the brake as firmly as necessary. This mechanical brake is also the parking brake and sets automatically when the spring-loaded steering arm is released and returns to the upright position. This action also cuts off electrical power to the dive motor.
Raising and lowering of the forks is controlled by the lift control handle (M) located on the right side of the mast. Move the control handle forward to raise the forks and to the rear to lower the forks.

OPERATING PRECAUTIONS
1. Do not exceed the rated capacity of the lift truck as indicated on the identification plate (K, fig. 1) located on the right side of the mast. Overloading will result in damage to lift mechanism.
2. To huard against tipping or hitting overhead obstructions, always lower the load when traveling.
3. When stacking pallets in racks, it is necessary to move the load in the raised position. Use care when turning at a right angleand use the slower speeds for moving the load when it is in a high position.
4. For general use, the mechanical brake is pre-set for a definite braking action. The first speed forward in the opposite direction of travel can be used for more braking action if needed.
5. When working on ramps, if the electrical brake is not sufficient, use the mechanical brake. Always make sure the brake is properly adjusted and in good working order.
6. Do not pick uploads on the tips of the forks. Center the loads as far back as possible toward the lift carriage.
7. Do not pick up loads on only one fork.
8. Do not use brake fluid in the hydraulic system. Use recommended oil listed in lubrication only.
9. Do not allow the spring-loaded steering arm to snap up to the vertical position. Hold the arm and allow to raise slowly when applying the parking brake.
WARNING: Do not work on, or service lift truck with the lift in a raised position without first putting a safety block under the lift to prevent accidental lowering of the lift. Raise lift before removing blocks after work is completed.

BATTERY CARE

BATTERY CARE
The life of the battery will be determined to a great extent by the care given it. Maintain the water level above the plates at all times. Add distilled or filtered water to bring the level up to but not into the neck of the battery cell. Keep the battery charged. Use a charger that charges at a maximum rate of not more than 75 amperes when the battery is down and automatically decreases the charging rate as the battery approaches full charge, then finally goes to a trickle of 2 amperes or less to equalize the cells.
CHARGING THE BATTERY
The approximate length of time required to fully charge the battery when down is ten to twelve hours with the charger supplied with the unit. To put the battery on charge, open the cover and remove the vent caps from the battery. Inspect the electrolyte level in each cell. Add distilled or filtered water to maintain the level above the plates at all times. Place the A.C. power switch of the battery charger in the ‘OFF’ position. Plug the A.C. power cord into a 115-volt single phase 60-cycle receptacle. Remove the upper half of the battery disconnector into the plugfurnished on the charger cable. Then snap the A.C. power switch to the ‘ON' position. (When the battery is charged, be sure to replace the vent caps before using the truck.)
The charger is made to charge 12-volt 6-cell 1260-1275 specific gravity lead acid batteries. It is automatic in its operation to correctly charge the battery commencing at maximum charging rate when the battery is down and gradually tapers off to 2 amperes or less when the battery is fully charged.
CAUTION: Make sure the battery charger is plugged into the battery connector and not the lower connector. Do not plug the 115-volt charger into a wall outlet that carries 220 or 440 volts. Do not connect or disconnect the battery with the A.C. power switch on the battery charger turned on.
INSPECTION MAINTENANCE AND SERVICE
GENERAL
Your Big Joe lift truck has been engineered to provide a long and useful life with a minimum of maintenance. It is important to follow the operating instructions carefully and not to overload the lift truck. In addition,

careful attention to the following maintenance and lubrication procedures will eliminate unnecessary repair costs.
The following periodic inspection and service table is based on a normal usage of eight hours per day, five days per week. If the lift truck is used more or less, the frequency of inspection and service should be changed accordingly.

HOW TO ORDER PARTS

When ordering parts, please state: quantity required, part number, part name and give the model and serial number of your machine.

For example: One 1645 Battery for Model PD20-58 Lift Truck, Serial No. 123.

DO NOT ORDER BY INDEX NUMBERS.

INSPECTION, SERVICE AND MAINTENANCE

INSPECTION AND SERVICE CHART
INTERVAL	INSPECTION	SERVICE
Weekly	Check condition of battery	Add water to maintain level above plates at all times
Weekly	Grease and oil	See lubrication instructions, Page 6
Weekly	Operate lift truck for final weekly inspection	Make any adjustments or service necessary
Monthly	Inspect transmission and drive unit for free operation and oil leaks.	Replace oil seal in axle housing if leaking, tighten bolts on cover if necessary. Replace O-Ring on motor face if leaking
Monthly	Drive motor commutator, brushes and springs	Worn commutator should be removed from motor and reconditioned, Replace worn brushes
Monthly	Check parking brake adjustment	Adjust parking brake linkage
Monthly	Hydraulic pump motor	Worn commutator should be removed from motor and reconditioned. Replace worn brushes.
Monthly	Check hydraulic system for leaks and oil level	Tighten loose and replace defective fittings. Add oil to the proper level. Foaming oil through the vent is usually caused by a leak in the suction line between the hydraulic pump and oil reservoir. A magnetic drain plug is furnished in the oil reservoir to trap any particles of steel that may be present in the hydraulic system.
Monthly	Inspect electrical panel for dust	Clean out dust with blow gun using dry air
Monthly	Check magnetic contactor tips	File off any high spot, replace if badly worn. Do not use emery cloth or sand paper to clean tips. A black appearance where tips make contact is normal
Monthly	Check electrical wiring	Be sure to check the 5-amp fuse located in the electrical circuit. Clean and tighten any loose connections.
Monthly	Check load wheels for wear	Replace if worn
Monthly	Check drive wheel for wear	Replace if worn
Monthly	Check caster wheels for wear	Replace if worn
Monthly	Operate lift truck for final monthly inspection	Make any adjustments or service necessary

MAINTENANCE LUBRICATION INSTRUCTION

LUBRICATION INSTRUCTIONS

LOCATION	LUBRICANT
A.Pivot tube bearings	Apply grease with brush to moving parts.
B. Steering Arm elbow	1 or 2 drops of oil each time serviced.
D. Upper mast rollers	Grease with pressure gun.
E. Ram head sheaves	Grease with pressure gun.
F. Lift carriage rollers	Grease with pressure gun.
G. Lower inner mast rollers	Female grease fitting-use pressure gun with point.
H. Mast & Inner mast	Apply grease with brush full length of channel where rollers operate.
I.Front wheels	Zerk fitting recessed in axle, grease with pressure gun.
J. Rear casters	Grease with pressure gun on swivel and wheel.
K. Transmission	Remove oil level plug and check level. Fill with No. 80 transmission oil to fill line.
L. Drive Motor	Bearings sealed, no lubrication.
M. Hydraulic System	Amount of oil necessary will vary with lifting height of truck. Enough oil should be in reservoir for maximum lift plus 2” reserve in tank.
N. Hydraulic Pump Motor	2 to 3 drops of light oil at each servicing in upper oil cup.
RECOMMENDED LUBRICANTS
Hydraulic System	Use a hydraulic oil with a viscosity of 150 Saybolt Universal seconds. In temperatures below 20 degrees F use 100 S.U.S. oil.
Transmission	Use No. 80 transmission oil.
Grease	Lithium base general purpose grease.
For best results use Big Joe Hydraulic and transmission oil.

MAINTENANCE, ADJUSTMENTS AND PARTS REPLACEMENT

3. Pull the cable up through the pivot tube to eliminate any slack, but do not apply tension on the cable. Fasten firmly with clamp (A) to the pivot offset elbow.
4. With the steering arm in ‘UP’ position, pull the cable through opening in the steering arm until it is firmly wrapped around spool (fig. 4) Slack off cable one inch and fasten with clamp at (B. fig. 4) in operator's handle to hold cable setting in a fixed position. The electrical control cable should be adjusted so it will work in the handle elbow without pulling on the spool or crowding the wire. The cable makes one full loop in the elbow, expands when the handle is in the ‘DOWN’ position and contracts when in the ‘UP’ position.
CAUTION: Improper adjustment will damage the cable. IF it is too short, it will tear when the operator's handle is in the ‘UP’ position and if it is too long it will buckle or be pinched when the handle is in the ‘DOWN’ position.
TRANSMISSION MAINTENANCE
The transmission, which is bolted directly to the pivot tube, does not require replacement for normal maintenance of the lift truck. The drive motor may be removed without disassembling the transmission by removing the two cap screws (40, fig. 9) and four motor wire leads. If replacement of the oil seal or disassembly of the transmission is required, jack up the rear of the truck until the drive wheel clears the floor. Remove the cover at the rear of the truck. Remove drain plug and drain oil. Disassemble the transmission in the following sequence:
1. Remove the bolts which hold on the cover; also the center bolt in the pinion shaft cover plate and turn into this a bolt with enough thread to act as a puller. When the pressure is applied on the center pinion tap the cover around the edge with a marproof hammer or pry with a screw driver to loosen it. The cover must be removed evenly to prevent a bind on the three dowel pins which hold it in alignment.
2. With the cover removed, the intermediate gear and the spur pinion can be taken out through the opening.
3. Remove rear axle locknut. To do this, use a punch or screw driver to flatten down the tab on the lockwasher and turn off the locknut. The axle assembly will now be free and can be removed from the drive wheel end.

4. Reassemble, working backward from the disassembly procedure. To adjust the Timken bearings in the axle assembly, turn the locknut tight, then back off and tighten to 20 to 30" lbs. torque. Use a new gasket when replacing the transmission cover. Adjust the end plate of the pinion counter-shaft for .010 to .020 clearance. Thsi can be done by shimming between the cap that covers this and the inner bearing race on the shaft.
The transmission assembly can be removed from the truck by taking off the four motor wire leads, disconnecting the brake linkage (7, fig. 16) where it connects to (8, fig. 16) located between the drive motor and the transmission frame, and by removing the four cap screws (8, fig. 9) and the lockwashers (7, fig. 9). The unit will now be free to be taken from the machine.
THROTTLE VALVE ADJUSTMENT (figure 5)
The throttle valve assembly controls the raising and lowering of the forks. When the handle on the valve is moved forward, a contact switch is actuated which starts the hydraulic pump motor.Hydraulic fluid, under pressure, causes the cylinder to raise the lift mechanism. To lower the lift mechanism, the hydraulic pressure is released by moving the handle on the valve to the hydraulic reservoir thereby lowering the lift mechanism.
The throttle valve is properly adjusted, inspected, and checked thorougly before leaving the factory. It should rarely need readjusting but if it should the following procedure should be used to set the valve and contact switch.
1.With the ball seeat assembly in place and the valve installed in the hydraulic system raise the lift mechanism part way with a moderate load on the forks to build up pressure in the hydraulic system.
2. Loosen upper nut (index E, fig. 5) on handle clamp (index F) being careful that the block does not come off the cam and allow the torsion spring to slip by the pins which keep it centered and in a neutral position.
3. Pull handle back ¾" from neutral position at (index D) on the throttle valve. With a screw driver in slot of cam, rotate 1/8" clockwise. This is to make sure the ball is seated in the valve seat (section AA, fig. 5). Turn counterclockwise until a definite resistance is felt. (Resistance is felt as the pin resting on the ball

pushes against the hydraulic pressure in the system. At this point the cam action has moved the plunger pin down against the check ball. Rotation of the cam beyond this point pushes the ball from the seat and opens the system allowing the lift mechanism to descend.
4. When the point of resistance is felt and with the handle pulled back ¾" at (index D, fig. 5), tighten nut (index E, fig. 5) on the handle clamp. The valve should now be in proper adjustment. Test by pulling the handle back 1" and lift carriage should try to slowly descend.
5. When the release cam is properly set it may be necessary to readjust the hydraulic pump motor switch (J, fig. 5). A clearance of approximately .010 inches should be maintained between the switch plunger (index K, fig. 5) and the valve cam clamp (F, fig. 5) for precise control of the lift mechanism. To adjust for proper clearance,

loosen the two nuts (G, fig. 5) and adjust the switch position on the bracket to give the required clearance. This adjustment should be made after setting the release cam.
Should a downward drift of the lift occur after adjusting, it could be that the ball seat is damaged. However, it is usually caused by some foreign material lodged between the throttle valve ball (index C, fig. 5) and ball seat, which allows leakage of hydraulic fluid past the seat. Normally this condition may be eliminated by operating the control handle forward and backward a few times. If this does not clear the valve, disconnect the tube at the bottom of the throttle valve and remove the hex head retaining screw (A, fig. 5) compression spring (B, fig. 5) and check ball (C, fig. 5). Check for foreign material on the ball or ball seat. Wipe the parts clean and reassembly the ball, spring, and retaining screw and reconnect the tube. Check operation of the lift.

If the downward drift of the load still occurs, this could be caused at the motor check valve. There is also a remote chance of leakage around the packing in the hydraulic cylinder. Check out the motor check valve by removing the hex head fitting on the back side of the hydraulic pump and taking out the spring and ball check. Inspect the ball and seat for damage; also for foreign particles that may be lodged here. Use a small mirror to do this on the far side of the pump. Clear out any foreign material, reassemble the pump check valve and check the operation of the lift.
CHAIN LENGTH ADJUSTMENT
Two heavy duty link chains raise the lift mechanism. Each chain is secured to the lift mechanism by a chain adjusting bolt, two nuts, and a lockwasher. The chains should be adjusted to equal tension and to the desired length. To adjust the length of the chains, loosen the top locknuts (54, fig. 7) and take up the slack in the chains with the ful nut below on the adjusting bolt. Tighten the locknuts securely after making the adjustment.
CONTACTOR TIP REPLACEMENT
When the contactor tip material is almost completely worn away, the tips must be replaced. The contact finger springs (10, fig. 18) should also be replaced at the same time.
RESISTOR-ADJUSTING SPEED
The speed of the truck in first and second speeds is controlled by a resistor (refer 6, fig. 18) installed between a field and negative side of the battery. Change the terminal connectors if the travel in a certain speed is not satisfactory. Shortening the resistance strip will increase the speed of travel; legthening the resistance strip will slow the speed of travel. Speeds acan be adjusted as wanted by changing the terminal connectors to a new location. When doing this make certain they and the terminals are bright and clean to assure a good connection.
HYDRAULIC PRESSURE ADJUSTMENT
The hydraulic pump is factory set to lift a load of the rated capacity of the truck (not to exceed 2000 psi) and rarely needs adjusting. However, should this be necessary, remove the acorn nut on the hydraulic pump and insert a screw driver into screw slot.
CAUTION: Do not set pressure too high or lift mechanism may be damaged and system overloaded.
Rotate clockwise to increase the counterclockwise to decrease the pressure. Refer to A, fig. 12.

FLOW CONTROL VALVE ADJUSTMENT
The flow control valve, located on the bottom of the hydraulic cylinder, controls the lowering speed of the forks. It also acts as a safety device in the event of loss of hydraulic pressure to permit the load to descend slowly. An adjustment is provided to permit the lowering speed of the forks to be varied. Hex nut should be loosened before adjustment is made and retightened after adjusting the valve. Rotate the adjustment counterclockwise to increase the clockwise to decrease the lowering speed of the forks. Refer to figure 14.
CAUTION: Do not adjust the flow control valve while the hydraulic system is under pressure. Be sure to use safety block when working under lift carriage.
ELECTRICAL CIRCUIT
The following information on how the electrical circuit functions will be helpful to one servicing the machine. All primary motor circuits are closed by a control circuit which energizes magnetic coils that are operated by butterfly controls located in the operator's handle.
Current is supplied to the control circuit as shown on the wiring digram, figure 17. This wire is protected by a 5-ampere fuse located on the electrical panel.
NOTE: BE SURE TO CHECK THE FUSE FIRST WHEN CHECKING OUT THE ELECTRICAL CIRCUIT.
From this point the wire follows through the dead man switch located on the brake linkage of the transmission. The wire then follows up through the control cable to the operator's handle to the center blade (D fig. 6) of the travel control switch. Pressing the butterfly control (A) on speed control part way down to where contact is made with the first blade (E) closes the circuit and energizes the forward (F fig. 6) or left side of the reversing contactor completing the first speed in a forward direction. Further advancing of the butterfly control downward until the contact is made with the next blade (G) energizes contactor (H, fig. 6) to complete the second speed in a forward direction. Still further advancing of the butterfly control until contact is made with the next blade (J) energizes contactor (K, fig. 6) to complete the third speed in a forward direction.
For a reverse direction of travel, depressing the butterfly control (B) until contact is made with blade (L) energizes reversing contactor (M, fig. 6) to com-

plete the first speed in a reverse direction. Further advancing of the butterfly control downward until contact is made with the next blade (N) energizes contactor (H, fig. 6) to complete the second reverse speed. Continuing to advance the butterfly control downward until contact is made with blade (P) energizes contactor (K, fig. 6) to complete the third speed in a reverse direction.
To set the dynamic brake, press the button (C) located in the center of the butterfly control. This will

open control circuit at switch (R) and simultaneously set the dynamic brake. The deadman switch (index 13, fig. 16) located on the brake linkage above the drive transmission opens the control circuit when the operator's handle is raised to its upper forward position. At this point the mechanical brake automatically takes over for parking. This same brake can be used to brake the truck at any time. It is recommended to use the mechanical brake when going down inclines or step ramps.

FRAME ANF LIFT ASSEMBLIES

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	1981	Base and Frame Assembly	1	16	810	Lockwasher – 5/8”	2
2	1714	Roller, I Beam	6	17	1984	Inner Mast Stop	1
3	1715	Roller Bearing	8	18	906	Door Latch	1
4	1987	Washer	8	19	2337	Bushing, Wheel Axle	2
5	859	Grease Fitting	16	20	1843-3	Roll Pin – 3/16” x 1-1/2”	2
6	893	Chain	2	21	1777-1	Roller Axle	2
7	903	Clevis Pin	4	22	2551	Washer – 2-1/2” O.D. x 1-1/64” I.D.	8
8	1495-1	Cotter Pin	4	23	1644-31	Seal, Wheel	4
9	832-6	Hex Hd. Cap Screw – ¼-20 x ¾” Lg.	4	24	1674	Roller Bearing and Sleeve	2
10	852	Lockwasher – ¼”	12	25	845	Retaining Ring	2
11	1808	Throttle Valve Assembly (See figure 5 on Pg. 9)	1	26	1679	Caster Swivel – Complte with Wheel	2
12	1707	Throttle Valve Guard	1	26A	2336	Caster Switvel – Only	2
13	817-4	Round Hd. Mach. Screw – ¼-20 x ½” Lg.	8	27	822-8	Hex Hd. Cap Screw – ½-13 x 1” Lg.	8
14	2560-18	Hex Hd. CapScrew – - 5/8-11 x 2 – ¼” Lg.	2	28	1679-1	Wheel Axle	2
15	2561	Hex Nut – 5/8-11 NC (not shown)	2	29	1644-27	Seal, Wheel	4
To order parts… please state: quantity required, part number, par name, the model and serial number of truck.				30	1471	Wheel, Rear Caster – 6” x 2-1/2”	2

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
31	967	Roller Bearing (Rear Caster Wheel)	2	46	1633	Ram Head	1
32	1720	Roller	2	47	868	Lockwasher	1
33	1679-2	Lock Nut	2	48	822-10	Hex Hd. Cap Screw – ½-13 x 1-1/4” Lg.	1
34	804	Lockwasher- ½”	8	49	1574	Bearing Ram Head	2
35	821	Hex Jam Nut – ½”	8	50	2324	Sheave	2
36	1700	Base Access Cover	1	51	1571	Bushing	2
37	2508-4	Flat Hd. Mach. Screw – 3/8-16 x ½” Lg.	4	52	1572	Retaining Ring	2
38	1688	Control Cabinet Cover	1	53	366	Chain Adjusting Bolt	2
39	905	Door Catch	1	54	813	Hex Nut – 5/8-18	2
40	850	Hex Nut – ¼”	3	55	810	Lockwasher – 5/8”	2
41	1645	Battery	1	56	814	Jam Nut – 5/8-18	2
42	1646	Battery Connector	1	57	1271	Lift Carriage Assembly	1
43	1819	Inner Mast Assembly	1	58	1905	Lift Fork Shaft	1
44	813	Hex Nut, 5/8-18	2	59	1859	Lift Fork	2
45	2504-28	Hex Hd Cap Screw, 5/8-18 x 3-1/2” Lg.	2	60	2513	Retaining Ring	2

STEERING ARM AND PIVOT TUBE ASSEMBLIES

Index Number	Part Number	Part Name	Number Required
1	917-4	Round Hd. Mach. Screw – ¼-20x ½” Lg.	2
2	852	Lockwasher – ¼”	5
3	1908	Locking Plate	1
4	1734	Pivot Pin	1
5	1658	Pivot Cap	1
6	1661	Pivot Cover	1
7	2502-6	Socket Hd. Cap Screw – 3/8 – 16 x ¾” Lg.	2
8	2540	Locknut	1
9	868	Lockwasher – ½”	1
10	1872	Control Cable Clamp and Nut	2
11	2511-8	Flat Hd. Screw – ¼-20 x 1” Lg.	1
12	832-10	Hex Hd. Screw – ¼-20 x 1” Lg.	1
13	1709	Return Spring	1
14	1748	Spring Hub	1
15	1600-1	Roll Pin	1
16	1749	Cable Guide	1
17	1879	Brake Lever	1
18	1775	Connector, Female	1
19	1774	Connector, Male	1
20	839-11	Round Hd. Mach. Screw - #5-40 x 1-3/8” Lg	2
21	840	Lockwasher	2
22	1845	Speed Control Switch Assembly	1
23	1876	Retaining Ring	2
24	1878	Washer	2
25	1652	Compression Spring	2
26	1877	Washer	2
27	1767	Plunger Guide	1
28	1787	Locknut	1
To order parts… please state: quantity required, part number, par name, the model and serial number of truck.

Index Number	Part Number	Part Name	Number Required
29	1684	Switch, Electric Brake & Safety Switch	2
30	1776	Spacer	1
31	2545	Locknut	1
32	2544	Locknut	1
33	1769	Cover Assembly	1
34	1655	Handle Grip	2
35	1651	Plunger	1
36	1653	Connecting Ling	1
37	1650	Speed Control Lever	1
38	1695	Brake Button	1
39	1677	Brake Switch Guide	1
40	1678	Brake Switch Pin	1
41	1600-3	Roll Pin – ¼” x ¾” Lg.	2
42	2539-8	Socket Hd. Cap Screw – 5/16-18x1” Lg.	4
43	801	Lockwasher – 5/16”	4
44	1773	Handle Guard	1
45	1979	Handle Guard Spring	1
46	1660	Handle	1
47	2541-3	Slotted Hd. Mach. Screw - #10-24 x 3/8” Lg.	4
48	1804	Access Cover	1
49	865-5	Socket Hd. Cap Screw – ¼-20 x 5/8” Lg.	2
50	1598	Flange Bushing, Upper	1
51	1873	Pivot Tube Assembly	1
52	1824	Thrust Bearing Assembly	1
53	1643	Traction Spring	1
54	1972	Spring Support Pin	1
55	1755-1	Cotter Pin – 3/32” x ¾” Lg.	1
56	1599	Spring Support	1
57	1642	Snap Ring	1
58	1597	Flange Bushing, Lower	1
59	2331	Spring	1
60	2330	Bushing	2
To order parts… please state: quantity required, part number, par name, the model and serial number of truck.

TRANSMISSION ASSEMBLY

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	1632-1	Cotter Pin – 1/8” x 1-1/4” Lg.	1	22	1540	Lockwasher	1
2	965	Hex Nut – 4/8-18 NF	1	23	1539	Locknut	1
3	1588	Motor Spur Pinion	1	24	1727	Ball Bearing	1
4	1639	Motor Pinion Spacer	1	25	2546-1	Key, Sq. -5/16” x 1-3/8” Lg.	1
5	1621	Dowel Pin	3	26	1594	Spur Pinion	1
6	1596	Transmission Housing	1	27	1589	Gear	1
7	804	Lockwasher – ½”	4	28	1638	Pinion Spacer	1
8	2503-10	Hex Hd. Cap Screw – ½-13 1-1/4” Lg.	4	29	1626	Ball Bearing	1
9	1873	Pivot Tube Assembly	1	30	1682	Bearing Cap Spacer	1
10	1021	“O’ Ring	1	31	1629	Cover Gasket	1
11	1587	Drive Motor Assembly (see figure 11, Pg. 18)	1	32	1595	Transmission Cover	1
12	1529	Brake Assembly (see figure 16, Pg. 23)	1	33	805	Lockwasher – 3/8”	11
13	2504-8	Hex Hd. Cap Screw – 5/8-18 x 1” Lg.	5	34	2505-14	Hex Hd. Cap Screw – 3/8-16 x 1-3/4” Lg.	7
14	810	Lockwasher – 5/8”	5	35	1681	Bearing Cap Gasket	1
15	1521	Drive Wheel Tire 10”, Rubber	1	36	1680	Bearing Cap	1
	1521-1	Drive Wheel Tire 10”, Polyurethane	1	37	801	Lockwasher – 5/16”	4
16	1374	Drive Wheel	1	38	818-8	Hex Hd. Cap Screw – 5/16-18 x 1” Lg.	4
17	1346	Axle Shaft	1	39	1846	Vent	1
18	1530	Oil Seal	1	40	20505-30	Hex Hd. Cap Screw – 3/8-16 x 3-3/4” Lg.	2
19	1531	Roller Bearing	2	41	2505-18	Hex Hd. Cap Screw – 3/8-16 x 2-1/4” Lg.	2
20	1647	Drain Plug	2
21	1591	Gear	1
To order parts… please state: quantity required, part number, par name, the model and serial number of truck.

Note: Complete Transmission Assembly may be exchanged for a complete factory rebuilt assembly by ordering Part. No. 1875 Exchange, or Transmission Assembly with Motor and Brake Assembly, No. 1988 - Transmission Assembly ONLY - less Motor and Brake Assembly No. 1990.

DRIVE MOTOR ASSEMBLY

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	2806	Drive End Head	1	13	2800	Commutator End Head	1
2	1625	O-ring	1	14	852	Lockwasher – ¼”	12
3	1534	Ball Bearing, Drive End	1	15	865-5	Socket Hd. Cap Screw – ¼-20 x 5/8” Lg.	12
4	2802	Armature Assembly	1	16	2808	Brush Set	4
5	2803	Frame and Field Assembly	1	17	2801	Brush Holder Assembly	1
6	2804	Field Coil Assembly	1	18	2521	Flat Washer – ¼”	2
7	2805	Pole Shoe	4	19	2522	Lockwasher – ¼”	2
8	2807	Cover Band	1	20	2520-5	Slotted Shoulder Screw - #10-32 x 5/8” Lg.	2
9	2517-5	Hex Hd. Bolt - #10-32 x 5/8” Lg.	1	21	2515-12	Round Hd. Mach. Screw - #10-32 x 1-1/2” Lg.	1
10	2518	Flat Washer - #10	1	22	2516	Nut, Square - #10-32	1
11	2523	Flat Washer, 3/32” thk – 3/16” I.D. x ½” O.D.	3	To order parts… please state: quantity required, part number, par name, the model and serial number of truck.
12	2809	Ball Beraing, Commutator End	1

Note: Complete Drive Motor Assembly may be exchanged for a complete factory rebuilt by ordering Part No. 1587 Exchange, or a new motor assembly by ordering Part No. 1587.

HYDRAULIC PUMP AND MOTOR ASSEMBLY

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	2834	Hydraulic Pump, Complete	1	13	2515-12	Round Hd. Mach. Screw - #10-32 x 1-1/2” Lg.	1
2	2838	Gasket	1	14	2831	Brush, Set of Four (4)	1
3	2548	Hex Nut – 5/16-24	2	15	2827	Motor Assembly	1
4	801	Lockwasher – 5/16”	6	16	818-6	Hex Hd. Cap Screw – 5/16-18 x ¾” Lg.	4
5	1969	Terminal Strap	1	17	2835	Drive Connector, Motor to Pump	1
6	2833	Solenoid Switch	1	Note: Complete Hydraulic Pump and/or Motor Assembly may be exchanged for a complete factory rebuilt assembly by ordering the following Exchange Part Numbers. For Hydraulic Pump Assembly ONLY – No. 2834 Exchange. For Motor Assembly ONLY – No. 2827 Exchange.
7	2549-3	Round Hd. Mach. Screw – ¼-20 x 3/8” Lg.	2
8	805	Lockwasher – 3/8”	2
9	812	Hex Nut – 3/8-16	2
10	2550	Oil Cup	1
11	2516	Square Nut - #10-32	1
12	2832	Cover Band	1

HYDRAULIC LIFT CYLINDER

TRUCK MODEL NO.		PD20-56	PD20-58	PD20-66	PD20-84	PD20-84	PD20-104	PD20-121	PD20-144
CYLINDER ASSY NO.		741	741	742	742	743	744	745	746
Index No.	Part Name	Part No.	Part No.	Part No.	Part No.	Part No.	Part No.	Part No.	Part No.	Qty Per Unit
1	Tube Assembly	640-10	640-10	640-11	640-11	640-12	640-13	640-9	640-14	1
2	Wiper Ring	649	649	649	649	649	649	649	649	1
3	Gland Nut	643	643	643	643	643	643	643	643	1
4	“O” Ring	648	648	648	648	648	648	648	648	1
5	Cylinder Ram	758-10	758-10	758-11	758-11	758-12	758-13	758-9	758-14	1
6	Ram Stop	645-4	645-4	645-4	645-4	645-3	645-3	645-3	645-3	1
7	“O” Ring	615	615	615	615	615	615	615	615	1
8	Piston	638	638	638	638	638	638	638	638	1
9	Packing Assy (4 rings)	634	634	634	634	634	634	634	634	1
10	Bottom Washer	647	647	647	647	647	647	647	647	1
11	Jam Nut ¾-16	626	626	626	626	626	626	626	626	1
12	Roll Pin 5/16x3/4 Lg.	825-1	825-1	825-1	825-1	825-1	825-1	825-1	825-1	1

HYDRAULIC SYSTEM

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	2825	Hydraulic Pump and Motor Assembly	1	13	1359	Complete Fitting, 90° Elbow	2
2	2535	Nipple	2	14	2556	90° Elbow	1
3	2536	90° Elbow	1	15	2557	Tubing Assembly	1
4	2533	Bushing	2	16	2555	Tee	1
5	803	Hose Clamp	2	17	2558	Tubing Assebly	1
6	177	Nipple	2	18	2554	Straight Fitting	2
7	864-2	Hose	1	19	1808	Throttle Valve Assembly	1
8	2532	90° Street Elbow	1	20	1703	Tubing	1
9	1795	Reservoir	1	21	2559	Tubing Assembly	1
10	2524	90° Elbow	2	22	379-2	Flow Control Valve	1
11	2525	Nut	2	23	2526	90° Street Elbow	1
12	1906	Tubing	1	24	161	Breather Cap	1

THROTTLE VALVE ASSEMBLY

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	1808	Manual Valve Assembly, Complete	1	15	1798	Valve Pin	1
2	1797	Manual Valve Body – 3/8”	1	16	1059	Check Ball – 5/16” Dia.	1
3	1336	O-ring	1	17	1799	Compression Spring	1
4	1143	Release Cam	1	18	1800	Retaining Screw	1
5	1142-2	Switch Bracket	1	Note: Complete Throttle Valve Assembly may be exchanged for a complete factory rebuilt assembly by ordering Part No. 1808 Exchange. See details on Exchange Items on Pages 12 and 13.
6	817-3	Mach. Screw, Phillips Hd. , ¼-20 x 3/8” Lg.	2
7	1337-1	Roll Pin	2
8	1146	Handle Return Spring	1
9	1338	Handle, Plastic	1
10	1992	Throttle Valve Handle	1
11	1418	Jam Nut – 3/8-24	2
12	1144	Throttle Valve Clamp	1
13	2567	Motor Contact Switch	1
14	2547	Nut (Adjusting)	2

BRAKE ASSEMBLY AND LINKAGE

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	256	Clevis	2	19	1970	Brake Lever	1
2	1747	Upper Brake Rod, Adjusting	1	20	2552	Flat Washer	1
3	1755-1	Cotter Pin – 3/32” x ¾” Lg.	10	21	1968	Brake Backing Plate	1
4	1744	Brake Lever	2	22	1967	Camshaft Assembly	1
5	1363	Clevis Pin – 5/16”	4	23	1902	Brake Shoe	2
6	1745	Tube Brake Rod	1	24	1528	Brake Drum	1
7	1746	Brake Rod	1	25	810	Lockwasher – 5/8”	1
8	1756	Lower Brake Lever Assembly	1	26	2538	Locknut	1
9	1751	Brake Mounting Bracket	1	27	2512-1	Key, Square – ¼ x 1-1/4” Lg.	1
10	805	Lockwasher – 3/8”	2	28	818-5	Hex Hd. Cap Screw – 5/16-18 x 5/8” Lg.	5
11	820-8	Hex Hd. Cap Screw – 3/8-16 x 1” Lg.	2	29	801	Lockwasher – 5/16”	5
12	2327	Locking Plate	1	30	1901	Brake Shoe Return Spring	2
13	1685	Switch, Deadman	1	31	1966	Brake Shoe Holddown Spring	2
14	2574-8	Round Hd. Screw - #6-32 x 1” Lg.	2	32	1495-3	Cotter Pin	1
15	1753	Lower Brake Pivot Pin	1	33	2543	Hex Nut, Slotted – ¼-28	1
16	2537	Locknut	3	34	2542-9	Hex Hd. Cap Screw – ¼-28 x 1-1/8” Lg.	1
17	1796	Lower Brake Adjusting Rod	1	To order parts… please state: quantity required, part number, par name, the model and serial number of truck.
18	1757	Lower Brake Spring	1

ELECTRICAL WIRING DIAGRAM

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	1845	Speed Control Switch Assembly	1	9	1520	Magnetic Contactor	2
2	1735	Terminal Board	1	10	1518	Speed Control Resistor	1
3	1684	Switch. Elect. Brake and Safety	2	11	1704	Electric Brake Resistor	1
4	1646	Battery Connector	1	12	1702	5 Amp. Fuse	1
5	2567	Hydraulic Motor Switch	1	13	1694	Horn Button	1
6	2825	Hydraulic Pump and Motor Assembly	1	14	1693	Horn	1
7	1476	Forward and Reverse Contactor	1	15	1685	Switch, Deadman	1
8	1587	Drive Motor	1	16	2566	Solenoid – Electric Brake	1
To order parts… please state: quantity required, part number, par name, the model and serial number of truck.

ELECTRICAL PANEL ASSEMBLY

Index Number	Part Number	Part Name	Number Required	Index Number	Part Number	Part Name	Number Required
1	1556	Fuse Holder	1		224	Remote Control Extension Assembly, Complete	1
2	1735	Terminal Board	1	1	354	Magnet	2
3	1476	Forward and Reverse Contactor	1	2	223	Push Button Station	1
4	1520	Magnetic Contactor	2	3	222	Coil Cord	1
5	1704	Electric Brake Resistor	1	4	221	Male Plug	1
6	1518	Speed Control Resistor	1	5	220	Female Plug	1
7	2566	Solenoid – Electric Brake	1	6	2839	Hydraulic Pump W/ Remote Control – 3/8	1
8	1478	Contact Tip	8	To order parts… please state: quantity required, part number, par name, the model and serial number of truck.
9	1479	Hex Nut and Lockwasher - #8-32	8
10	1485	Contact Spring	2
11	1513	Magnet Coil	2
12	1497	Return Spring	2
13	1501	Magnet Core Assembly	2
14	1494	Spring Pin Assembly	2
15	1986	Electrical Panel Assembly

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DP SERVICE INSTRUCTIONS SELF PROPELLED STRADDLE LIFT TRUCK MODELS PD20-30 SERIES [PD20-30]

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