Big Joe PDI Series Operation Maintenance Manual & Parts List page 25

MALFUNCTION
Oil splashes out of vent when low-
ering forks.
Squealing sounds when lifting
forks.
Forks do not lift to top. Pump
motor runs.
Oil leaks out of lift control valve
release cam.
Lift control does not return to neu-
tral.
Weak, slow or uneven action of
hydraulic system.
Forks do not lift, motor does not
run.
Forks do not lift, motor runs.
Forks lift, but will not go down.
PDI0404
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Table 4-1 Troubleshooting Chart - Continued
PROBABLE CAUSE
Oil level too high.
a. Oil level too low.
b. Dry channels in mast.
c. Defective mast or carriage bear-
ing.
a. Oil level too low.
b. Load larger than capacity.
c. Batteries are dead.
Defective O-ring in lift control valve
body.
a. Broken return spring.
b. Foreign particles.
c. Misalignment of valve clamp.
a. Defective pump.
b. Defective lift cylinder.
c. Load larger than capacity.
d. Dirt or foreign particles lodged
between check ball and seat on
lift control valve.
e. Defective lift control valve.
f. Valve body scored inside.
g. Battery specific gravity low.
a. Battery is dead or discon-
nected.
b. Defective wiring.
c. Defect in electrical system for
operating pump motor.
Defective in hydraulic system.
Control valve in open position or
defect in hydraulic system.
CORRECTIVE ACTION
Drain, then refill reservoir to
"FULL" mark on dip stick.
Add oil to reservoir.
Apply grease.
Replace bearing.
Add oil to reservoir.
Refer to nameplate on side of
mast for maximum load capacity.
Recharge.
Replace O-ring on release cam
shaft.
Replace return spring.
Clean system and valve.
Adjust as required.
Check pressure.
Clean system and valve.
Refer to name plate on side of
mast for maximum load capacity.
Disassemble, clean and reassem-
ble valve.
Adjust, repair or replace.
Replace valve.
Charge battery.
Check and recharge if required.
Check and repair as required.
Check pump motor switch on lift
control valve, as well as the sole-
noid relays. Repair or replace.
Check the oil level in the reservoir
and the oil lines to the lift cylin-
der, and repair as required. If
normal, check the hydraulic
pump, oil filter, and lift control
valve. Repair or replace.
Check the lowering control valve
as well as the flow control valve,
and look for obstruction in the
hydraulic line. Repair or adjust
as required.
4-3