PDI SERIES - Big Lift, LLC Support Site for Big Joe Equipment

1 Big Joe Manufacturing Company Des Plaines, IL 60018 MANUAL NO. 901355 REV. B 0404 Manual Price $ SERIESPOWER DRIVE INTERMEDIATELIFT TRUCKS erial Number 333375 to 376499 OperationMaintenanceRepair Parts ListPDI0404iTABLE OF CONTENTSS ectionPageSectionPage1 DESCRIPTION .. FEATURES.. AND OPERATION .. PRECAUTIONS.. DRIVE CONTROL CONTROL HANDLE.. STEERING ARM CONTROLS.. AND STOPPING PROCEDURES.. SWITCH GUARD.. ARM RETURN SPRING.. CONTROL.. AND UNLOADING..2-72-10. PARKING..2-73 PLANNED MAINTENANCE .. AND QUARTERLY CHECKS.. CELL BATTERY CARE.. GENERAL.. TIMER CHARGER OPERATION.. SMART CHARGER CELL BATTERY CARE (OPTIONAL) .. GENERAL.. CHARGING BATTERIES .. REMOVING BATTERIES FROM CHARGER .. CHAIN TROUBLESHOOTING .. CHARGER 004978 TROUBLESHOOTING .. GEL CELL BATTERY CHARGER 004987 TROUBLESHOOTING .. DIP SWITCH SETTING .. CIRCUIT BREAKER TESTING .. POWER TRANSFORMER CIRCUIT BOARD STEERING ARM AND CONTROL HEADS SERVICING.

2 CONDITIONING.. SWITCH ADJUSTMENT .. HEAD SWITCH CONTROL SWITCH RETURN SPRING REPLACEMENT.. ARM RETURN SPRING ARM RETURN SPRING REPLACEMENT.. TUBE FLANGED BUSHING REPLACEMENT.. CONTROL CABLE REPLACEMENT.. 5-106 BRAKE SERVICING .. OF DISC BRAKE PARTS .. 6-27 TRANSMISSION, DRIVE WHEEL, ADJUSTABLE STRADDLE,AND LOAD WHEEL SERVICING .. DISASSEMBLY .. AXLE AND WHEEL OF MOTOR AND BRAKE ASSEMBLY INCLUDING DRIVE OF BRAKE DISC ASSEMBLY.. STRADDLE lift trucks .. WHEELS.. 7-48 ELEVATION SYSTEM SERVICING .. CHAIN LENGTH TELESCOPIC AND FULL FREE LIFT.. CHAIN WEAR CHAIN REPLACEMENT.. TELESCOPIC AND FULL FREE LIFT.. CYLINDER NON-TELESCOPIC.. TELESCOPIC.. FULL FREE LIFT.. HEAD REMOVAL.. NON-TELESCOPIC.. TELESCOPIC.. SHEAVE REPLACEMENT (FULL FREE LIFT).. OF 8-79 HYDRAULIC SYSTEM SYSTEM PRESSURE.. CONTROL VALVE REPLACEMENT.

3 LINE FILTER REPLACEMENT.. OR FITTING 9-4iiPDI0404 TABLE OF CONTENTS (Cont) CONTROL VALVE.. PUMP MOTOR SWITCH ADJUSTMENT.. PUMP AND MOTOR PUMP AND MOTOR ASSEMBLY REMOVAL. HYDRAULIC PRESSURE ADJUSTMENT.. CYLINDER REPAIR.. NON-TELESCOPIC.. TELESCOPIC.. FULL FREE LIFT.. 9-1010 ELECTRICAL COMPONENTS .. 10-110-1. ELECTRICAL CONTROL PANELS.. 10-110-2. CONTROL PANEL 10-110-3. CONTACTOR SERVICING. SERIAL NUMBER 333375 TO AND 3RD SPEED CONTACTOR DISASSEMBLY. SERIAL NUMBER 333375 TO AND 3RD SPEED CONTACTOR REASSEMBLY. SERIAL NUMBER 333375 TO CONTACTOR NUMBER 333375 TO 364407 .. CONTACTOR NUMBER 333375 TO 364407 .. 10-510-4. PUMP MOTORS.. 10-610-5. DRIVE 10-610-6. BATTERY 10-610-7. BATTERIES.. 10-810-8. 10-810-9. HIGH SPEED LIMIT 10-1010-10. 10-1011 OPTIONAL Equipment .. 11-111-1. KEYSWITCH .. 11-111-2. HOUR METER .. 11-111-3.

4 BATTERY CAPACITY INDICATOR.. 11-111-4. REMOTE CONTROL.. 11-111-5. REMOTE CONTROL BOX REMOTE HEAD LIFT/LOWER .. 11-112 ILLUSTRATED PARTS BREAKDOWN .. 12-1 LIST OF ILLUSTRATIONSF igurePageFigurePage1-1 NAME PLATE .. 1-11-2 SERIAL NUMBER AND DECAL LOCATION .. 1-31-3 PDI LIFT truck .. 1-42-1 LOAD 2-12-2 SAMPLE OF OPERATOR CHECK LIST .. 2-42-3 CONTROL HANDLE .. 2-52-4 STEERING ARM BRAKING POSITION .. 2-62-5 LIFT/LOWER 2-73-1 REINSTALLING THE BATTERY .. 3-23-2 CHARGE INDICATOR .. 3-43-3 LUBRICATION DIAGRAM .. 3-64-1 BATTERY CHARGER SCHEMATIC .. 4-54-2 LOGIC BOARD JUMPER POSITION .. 4-54-3 LOGIC FLOW DIAGRAM (SHEET 1) .. 4-64-4. DIP SWITCH SETTINGS .. 4-84-5. BATTERY CHARGER WIRING DIAGRAM .. 4-94-6 WIRING DIAGRAM (SHEET 1).. 4-104-7 WIRING DIAGRAM (SHEET 1).. 4-125-1 BELLY-BUTTON SWITCH 5-15-2 SCHEMATIC OF COLD CONDITIONING 5-15-3 LOCATION OF RESISTORS AND THERMAL CUTOUT 5-2 5-4 CONTROL HEAD ASSEMBLY.

5 5-35-5 PUSH BUTTON SWITCHES .. 5-55-6 STEERING ARM AND ELECTRICAL CABLE .. 5-75-7 PIVOT TUBE ASSEMBLY .. 5-85-8 PIVOT TUBE REMOVAL 5-95-9 ELECTRICAL CONTROL CABLE 5-116-1 BRAKE 6-16-2 ADJUSTMENT .. 6-26-3 PARTS 6-37-1 TRANSMISSION .. 7-27-2 ADJUSTABLE STRADDLE 7-37-3 LOAD 7-48-1 ELEVATION SYSTEM (TELESCOPIC) .. 8-18-2 ELEVATION SYSTEM (TELESCOPIC) .. 8-28-3 ELEVATION SYSTEM (NON-TELESCOPIC) .. 8-38-4 ELEVATION SYSTEM (FULL FREE LIFT) .. 8-49-1 HYDRAULIC SYSTEM 9-19-2 HYDRAULIC SYSTEM (TELESCOPIC AND NON-TELESCOPIC) .. 9-29-3 HYDRAULIC SYSTEM (FULL FREE LIFT).. 9-39-4 LIFT/LOWER CONTROL VALVE ADJUSTMENT .. 9-49-5 LIFT/LOWER CONTROL VALVE (STANDARD) 9-59-6 LIFT/LOWER CONTROL VALVE (COLD CONDITIONING).. 9-59-7 LIFT CYLINDER (NON-TELESCOPIC).. 9-89-8 LIFT CYLINDER (TELESCOPIC).. 9-99-9 LIFT CYLINDER (FULL FREE LIFT).. 9-1110-1 ELECTRICAL CONTROL PANEL .. 10-110-2 ELECTRICAL CONTROL PANEL.

6 10-2 PDI0404iiiLIST OF ILLUSTRATIONS (Cont)FigurePageFigurePage10-3 CONTACTOR (2ND AND 3RD SPEED) PART NUMBER 005659 ..10-410-4 CONTACTOR (FORWARD-REVERSE) PART NUMBER 005657 ..10-510-5 BATTERY CHARGER 004967-01 AND 004967-02 SCHEMATIC ..10-610-6 BATTERY CHARGER 004976-01 SCHEMATIC ..10-710-7 BATTERY CHARGER 004978 SCHEMATIC ..10-710-8 BASE, FRAME AND ELECTRICAL COMPONENTS ..10-910-9 ELECTRICAL CONTROL HEAD PUSH BUTTON SWITCHES, CONTROL COLD CONDITIONING, CONTROL STEERING ARM AND ELECTRICAL PIVOT TUBE ASSEMBLY ..12-812-6 BRAKE AND LINKAGE ..12-1012-7 TRANSMISSION ..12-1212-8 DRIVE MOTOR 016046 ..12-1412-9 DRIVE MOTOR 016052 ..12-1512-10 BASE AND FRAME ..12-1612-11 DECAL LOCATION ..12-1812-12 ADJUSTABLE STRADDLE LOAD ELEVATION SYSTEM (TELESCOPIC)..12-2012-15 ELEVATION SYSTEM (TELESCOPIC)..12-2212-16 ELEVATION SYSTEM (NON-TELESCOPIC) 12-2412-17 ELEVATION SYSTEM (FULL FREE LIFT).

7 12-2612-18 LIFT CARRIAGE AND HYDRAULIC SYSTEM (TELESCOPIC AND NON-TELESCOPIC)..12-3012-20 HYDRAULIC SYSTEM (FULL FREE LIFT) ..12-3112-21 LIFT CYLINDER (NON-TELESCOPIC)..12-3212-22 LIFT CYLINDER (TELESCOPIC) ..12-3412-23 LIFT CYLINDERS (FULL FREE LIFT) .. 12-3612-24 LIFT CONTROL VALVE (STANDARD) .. 12-3812-25 LIFT CONTROL VALVE (COLD CONDITIONING) .. 12-3812-26 BATTERIES .. 12-4012-27 QUICK DISCONNECT CABLE INSTALLATION .. 12-4212-28 ELECTRICAL COMPONENTS .. 12-4412-29 HYDRAULIC PUMP AND MOTOR 905046 .. 12-4612-30 HYDRAULIC PUMP AND MOTOR ASSEMBLY 12-4712-31 HYDRAULIC PUMP AND MOTOR ASSEMBLY 12-4812-32 HYDRAULIC PUMP AND MOTOR ASSEMBLY 12-4912-33 ELECTRICAL CONTROL PANEL .. 12-5012-34 ELECTRICAL CONTROL PANEL .. 12-5112-35 CONTACTOR (2ND AND 3RD SPEED).. 12-5212-36 CONTACTOR (FORWARD/REVERSE) .. 12-5212-37 "SMART" BATTERY CHARGER INSTALLATION.

8 12-5312-38 GEL CELL BATTERY CHARGER .. 12-5412-39 BATTERY CHARGER MOUNTING .. 12-5512-40 OPTIONAL "SMART" CHARGER 004976-01 (REPLACES TIMER CHARGER 004967-01) 12-5612-41 STANDARD TIMER BATTERY CHARGER 004967-01 AND 004967-02 .. 12-5712-42 OPTIONAL KEYSWITCH .. 12-5812-43 OPTIONAL HOUR 12-5812-44 OPTIONAL BATTERY CAPACITOR INDICATOR .. 12-5912-45 OPTIONAL BATTERY CAPACITOR INDICATOR .. 12-6012-46 OPTIONAL REMOTE CONTROL INSTALLATION .. 12-61 LIST OF TABLES (Cont)TablePageTablePage2-1 OPERATOR CHECKS ..2-23-1 MONTHLY AND QUARTERLY INSPECTION AND SERVICE CHARGER TIME FOR BATTERY CHARGING ..3-33-3 RECOMMENDED LUBRICANTS .. 3-53-4 LUBRICATION CHART .. 3-6 4-1 TROUBLESHOOTING CHART .. 4-110-1 BATTERY CHARGERS .. 10-6ivPDI0404 OPERATOR INSTRUCTIONSWARNINGDo not operate this truck unless you have been trainedand authorized to do so and have read all warningsand instructions in operator's manual and on this not operate this truck until you have checked itscondition.

9 Give special attention to Tires, Horn, Lights,Battery, Controller, Lift System, (including forks orattachments, chains, cables and limit switches),Brakes, Steering Mechanism, Guards and truck only from designated operating place any part of your body into the mast struc-ture or between the mast and the truck . Do not carrypassengers. Keep feet clear of applicable traffic regulations. Yield right ofway to pedestrians. Slow down and sound horn atcross aisles and wherever vision is , stop, travel, steer and brake smoothly. Slowdown for turns and on uneven or slippery surfaces thatcould cause truck to slide or overturn. Use specialcare when traveling without load as the risk of overturnmay be with lifting mechanism as low as look in direction of travel. Keep a clear view,and when load interferes with visibility, travel with loador lifting mechanism trailing, except when special care when operating on ramps travelslowly, and do not angle or turn.

10 Travel with liftingmechanism or load not overload truck . Check capacity plate for loadweight and load center using forks, space forks as far apart as load willpermit. Before lifting, be sure load is centered, forksare completely under load, and load is far back as pos-sible against load not handle unstable or loosely stacked loads. Usespecial care when handling long, high or wide loads toavoid losing the load, striking bystanders, or tippingthe not handle loads which are higher than the loadbackrest or load backrest extension unless load issecured so that no part of it could fall forks or other lifting mechanism only to pick upor stack a load. Watch out for obstructions, not lift personnel except on a securely attachedspecially designed Work Platform. Use extreme carewhen lifting personnel. Make sure mast is vertical,place truck controls in neutral and apply brakes.