SELF-PROPELLED, COUNTERBALANCED LIFT TRUCK

1 Big Lift LLCMANUAL NO. BL-C22-1010 - , COUNTERBALANCED LIFT TRUCKO perationMaintenanceRepair Parts ListWARNINGDo not operate this TRUCK unless you have been autho-rized and trained to do so, and have read all warningsand instructions in Operator s Manual and on not operate this TRUCK until you have checked itscondition. Give special attention to tires, horn, battery,controller, lift system (including forks or attachments,chains, cables and limit switches), brakes, steeringmechanism, guards and safety TRUCK only from designated operating place any part of your body into the mast struc-ture or between the mast and the TRUCK .

2 Do not carrypassengers. Keep feet clear of TRUCK and wear 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 special care when operating on ramps travelslowly, and do not angle or turn.

3 Travel with not overload TRUCK . Check nameplate for capacityand 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 as far back aspossible 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.

4 Watch out for obstructions, not lift personnel except on a securely attachedspecially designed work platform. USE EXTREMECARE WHEN LIFTING PERSONNEL. Make suremast is vertical, place TRUCK controls in neutral andapply brakes. Lift and lower smoothly. Remain in oper-ating position or immediate vicinity as long as person-nel are on the work platform. Never transportpersonnel on forks or work not allow anyone to stand or pass under load or lift-ing leaving TRUCK , neutralize travel control, fullylower lifting mechanism and set brake.

5 When leavingtruck unattended, also shut off OF CONTENTSBL-C22-1010 - 06-19-2017iSectionPageSectionPage1 DESCRIPTION .. FEATURES..1-12 OPERATION .. PRECAUTIONS.. CONTROL AND STOPPING PROCEDURES.. SWITCH.. ARM GAS , LOWER AND FAST LOWER CONTROLS.. AND UNLOADING..2-52-10. PARKING..2-53 PLANNED MAINTENANCE .. AND QUARTERLY CHECKS..3-13-3. BATTERY CARE.. GENERAL .. SAFETY RULES .. BATTERY CARE AND CHARGING .. BATTERY MAINTENANCE FREE BATTERIES .. CHAIN TROUBLESHOOTING .. FAULT DETECTION.. HAND HELD PROGRAMMER (OPTIONAL).

6 FAULT RECORDING.. FAULT RECOVERY.. GENERAL CHECKOUT.. DIAGNOSTIC HISTORY .. TEST THE FAULT DETECTION CIRCUITRY . PROGRAMMABLE PARAMETERS .. DIAGNOSTICS AND TROUBLESHOOTING. DIAGNOSTICS ..4-315 STEERING ARM, CONTROL HEAD AND COMPARTMENT .. HEAD .. CONTROL HEAD REMOVAL .. BELLY-BUTTON SWITCH REPLACEMENT.. LIFT, LOWER AND HORN SWITCH DIRECTIONAL SWITCH REMOVAL AND ADJUSTMENT.. POTENTIOMETER REMOVAL TESTING AND CONTROL HEAD INSTALLATION.. ARM .. RETURN AIR SPRING REPLACEMENT.. STEERING ARM REMOVAL.. STEERING ARM INSTALLATION.

7 FORWARD COMPARTMENT.. REAR INSTALLATION.. 5-66 BRAKE SERVICING .. AIR GAP ADJUSTMENT.. STOPPING DISTANCE ADJUSTMENT.. BRAKE ASSEMBLY REPLACEMENT .. 6-27 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL .. WHEEL.. WHEEL.. REMOVAL .. REPAIR .. LOAD WHEEL 7-38 ELEVATION SYSTEM SERVICING .. CHAIN LENGTH CHAIN WEAR CHAIN REPLACEMENT.. CYLINDER.. 8-39 HYDRAULIC SYSTEM AND FITTINGS .. PUMP, AND MOTOR ASSY .. REMOVAL .. DISASSEMBLY AND REASSEMBLY .. INSTALLATION .. LIFT CYLINDERS.

8 TILT CYLINDERS .. 9-510 ELECTRICAL COMPONENTS .. 10-110-1. ELECTRICAL CONTROL PANEL .. REMOVAL.. INSTALLATION.. 10-110-2. HORN REPLACEMENT .. 10-210-3. PUMP MOTOR.. 10-410-4. DRIVE MOTOR.. INSTALLATION .. 10-410-5. LIMITATION SWITCH .. 10-410-6. DEADMAN 10-511 OPTIONAL EQUIPMENT .. 11-112 ILLUSTRATED PARTS BREAKDOWN .. 12-1 TABLE OF CONTENTS - ContinuediiBL-C22-1010 - 06-19-2017 FigurePageFigurePage1-1 NAME 1-11-2 PDS LIFT TRUCK .. 1-22-1 LOAD CENTER .. 2-12-2 SAMPLE OF OPERATOR CHECK 2-32-3 FORWARD/REVERSE CONTROL.

9 2-42-4 PUSHBUTTON SWITCHES .. 2-42-5 BRAKE 2-42-6 BELLY-BUTTON SWITCH .. 2-53-1 LUBRICATION 3-54-1 CONTROLLER LED .. 4-44-2 CONTROLLER TERMINALS .. 4-54-3 HAND HELD PROGRAMMER .. 4-55-1 STEERING ARM .. 5-15-2 CONTROL HEAD .. 5-25-3 SWITCH 5-35-4 STEERING SYSTEM .. 5-45-5 COMPARTMENT .. 5-56-1 BRAKE ASSEMBLY .. 6-16-2 TRANSMISSION, MOTOR, BRAKE ASSEMBLY .. 6-26-3 STEERING SYSTEM .. 6-37-1 TRANSMISSION, MOTOR, BRAKE ASSEMBLY .. 7-17-2 FRAME .. 7-27-3 STEERING SYSTEM .. 7-27-4 LOAD WHEEL .. 7-38-1 OUTER MAST .. 8-18-2 INNER MAST.

10 8-29-1 HYDRAULIC SYSTEM .. 9-19-2 PUMP AND MOTOR 9-29-3 OUTER MAST .. 9-39-4 LIFT CYLINDER .. 9-49-5 TILT CYLINDER .. 9-510-1 FRAME .. 10-210-2 ELECTRICAL PANEL .. 10-310-3 TRANSMISSION, MOTOR, BRAKE 10-410-4 STEERING 10-512-1 STEERING 12-212-2 HANDLE ASSEMBLY .. 12-312-3 SWITCH BOX 12-412-4 SWITCH BOX .. 12-512-5 TRANSMISSION, MOTOR, BRAKE 12-612-6 TRANSMISSION, ASSEMBLY .. 12-812-8 COVER 12-912-9 FRAME .. 12-1012-10 CASTER .. 12-1112-11 LOAD WHEEL .. 12-1212-12 OUTER MAST .. 12-1312-13 INNER 12-1412-14 LIFT 12-1512-15 HYDRAULIC SYSTEM.