Table Of Contents - Big Lift Big Joe PDC Series Operation, Maintenance, Repair Parts List

Section
1 DESCRIPTION ...........................................................1-1
1-1. INTRODUCTION. .............................................1-1
1-2. GENERAL DESCRIPTION...............................1-1
1-3. SAFETY FEATURES. ......................................1-1
1-4. OPTIONS AND ACCESSORIES......................1-2
1-5. SAFETY SYMBOLS. ........................................1-2
2 OPERATION ...............................................................2-1
2-1. GENERAL. .......................................................2-1
2-2. OPERATING PRECAUTIONS. ........................2-1
2-3. BEFORE OPERATION.....................................2-2
2-4. INSTRUMENTS AND CONTROLS ..................2-4
2-4.1. STEERING ARM AND CONTROL HEAD. .......2-4
2-4.2. LIFT/LOWER AND TILT CONTROL. ...............2-5
2-4.3. BATTERY DISCONNECT. ...............................2-5
2-4.4. OPTIONAL FEATURES. ..................................2-5
2-5. OPERATION ....................................................2-5
2-5.1. FORWARD AND REVERSE TRAVEL AND 
SPEED CONTROL...........................................2-5
2-5.2. STEERING. ......................................................2-5
2-5.3. STOPPING. ......................................................2-6
2-5.4. PARKING. ........................................................2-6
2-5.5. BATTERY CHARGING.....................................2-7
2-5.6. LOAD HANDLING. ...........................................2-7
2-5.7. MOVING A DISABLED TRUCK .......................2-7
3 PLANNED MAINTENANCE ........................................3-1
3-1. GENERAL. .......................................................3-1
3-2. MONTHLY AND QUARTERLY CHECKS. .......3-1
3-3. BATTERY CARE. .............................................3-1
3-3.1. GENERAL. .......................................................3-1
3-3.2. BATTERY SERVICING. ...................................3-1
3-4. LUBRICATION. ................................................3-2
4 TROUBLESHOOTING ................................................4-1
4-1. GENERAL ........................................................4-1
5 STEERING ARM AND CONTROL 
HEAD SERVICING......................................................5-1
5-1. GENERAL. .......................................................5-1
5-2. COLD CONDITIONING. ...................................5-1
5-3. BELLY-BUTTON SWITCH ADJUSTMENT. .....5-2
POTENTIOMETER TESTING AND 
5-4.
ADJUSTMENT .................................................5-2
5-5. CONTROL HEAD SWITCH REPLACEMENT..5-3
SPEED CONTROL SWITCH AND RETURN 
5-6.
SPRING REPLACEMENT................................5-5
5-7. STEERING ARM RETURN SPRING
ADJUSTMENT. ................................................5-6
STEERING ARM RETURN SPRING 
5-8.
REPLACEMENT...............................................5-6
5-9. PIVOT TUBE REPLACEMENT. .......................5-7
5-10. ELECTRICAL CONTROL CABLE
REPLACEMENT...............................................5-8
6 BRAKE SERVICING....................................................6-1
6-1. ADJUSTMENT .................................................6-1
6-2. REPLACEMENT OF BRAKE PADS.................6-2
6-2.1. REPLACEMENT OF BRAKE DISC..................6-4
7 TRANSMISSION, DRIVE WHEEL AND 
LOAD WHEEL SERVICING ........................................7-1
TRANSMISSION REMOVAL AND 
7-1.
DISASSEMBLY ................................................7-1
7-2. DRIVE WHEEL REPLACEMENT.....................7-3
7-3. LOAD WHEELS. ..............................................7-3
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TABLE OF CONTENTS

Page Section
8 ELEVATION SYSTEM SERVICING ........................... 8-1
8-1.
8-2.
8-3.
8-4.
8-4.1. FULL FREE LIFT CHAIN ................................. 8-3
8-4.2. SECONDARY LIFT CHAINS ........................... 8-3
8-5.
8-6.
8-7.
8-8.
8-8.1. FULL FREE LIFT CHAIN ................................. 8-4
8-8.2. SECONDARY LIFT CHAINS ........................... 8-4
8-9.
8-10. LIFT CYLINDER REPLACEMENT 
8-11. LIFT CYLINDER REPLACEMENT 
8-11.1.FULL FREE LIFT CYLINDER.......................... 8-6
8-11.2.SECONDARY LIFT CYLINDERS .................... 8-6
8-12. TILT CYLINDER REPLACEMENT. ................. 8-6
8-13. HOSE BRACKET REPLACEMENT............... 8-10
8-14. MAST REMOVAL. ......................................... 8-10
8-15. LIFT CARRIAGE REPLACEMENT................ 8-10
9 HYDRAULIC SYSTEM SERVICING........................... 9-1
9-1.
9-2.
9-2.1. STANDARD TRUCKS. .................................... 9-1
9-3.
9-3.1. SUMP FILTER. .............................................. 9-10
9-4.
9-5.
9-6.
9-6.1. LIFT FLOW CONTROL VALVE ..................... 9-13
9-6.2. TILT FLOW CONTROL VALVE ..................... 9-13
9-7.
9-7.1. NON-TELESCOPIC, TELESCOPIC AND 
9-7.2. FULL FREE LIFT ........................................... 9-15
9-8.
9-8.1. BMP MODEL CYLINDER .............................. 9-16
9-8.2. CH MODEL CYLINDER................................. 9-17
9-8.3. EM MODEL CYLINDER ................................ 9-18
10 ELECTRICAL COMPONENTS ................................. 10-1
10-1. ELECTRICAL CONTROL PANELS. .............. 10-1
10-1.1.CLEANING .................................................... 10-1
10-1.2.PANEL REMOVAL. ....................................... 10-1
10-1.3.PANEL DISASSEMBLY................................. 10-1
10-1.4.CONTACTOR BOX DISASSEMBLY AND 
10-1.5.CONTACTOR SERVICING. .......................... 10-6
10-2. PUMP MOTORS............................................ 10-7
10-3. DRIVE MOTORS. .......................................... 10-7
10-4. BATTERIES. .................................................. 10-7
10-5. HIGH SPEED LIMIT SWITCH. ...................... 10-8
GENERAL........................................................ 8-1
LIFT CHAIN ADJUSTMENT 
(NON-TELESCOPIC, AND TELESCOPIC) ..... 8-1
LIFT CHAIN ADJUSTMENT 
(FULL FREE LIFT)........................................... 8-2
LIFT CHAIN ADJUSTMENT 
(CLEAR VIEW TRIMAST) ............................... 8-3
LIFT CHAIN INSPECTION .............................. 8-4
LIFT CHAIN REPLACEMENT 
(NON-TELESCOPIC, AND TELESCOPIC) ..... 8-4
LIFT CHAIN REPLACEMENT 
(FULL FREE LIFT)........................................... 8-4
LIFT CHAIN REPLACEMENT 
(CLEAR VIEW TRIMAST) ............................... 8-4
LIFT CYLINDER REPLACEMENT 
(NON-TELESCOPIC, AND TELESCOPIC). .... 8-5
(FULL FREE LIFT)........................................... 8-5
(CLEAR VIEW TRIMAST) ............................... 8-6
RELIEVING SYSTEM PRESSURE. ................ 9-1
LINE, FITTING AND HOSE REPLACEMENT. 9-1
FILTER REPLACEMENT. ............................. 9-10
HYDRAULIC PUMP AND 
MOTOR ASSEMBLY ..................................... 9-11
CONTROL VALVE REPLACEMENT............. 9-12
FLOW CONTROL VALVE REPLACEMENT 
(NON-TELESCOPIC AND TELESCOPIC) .... 9-13
LIFT CYLINDER REPAIR .............................. 9-14
CLEAR VIEW TRIMAST ................................ 9-14
TILT CYLINDER REPAIR .............................. 9-16
REASSEMBLY (TYPE EE TRUCKS ONLY). 10-1
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