Big Joe PDI Series Operation Maintenance Manual & Parts List page 4

Section
9-5. LIFT/LOWER CONTROL VALVE. ................... 9-4
9-5.1. ADJUSTMENT................................................. 9-4
9-5.2. DISASSEMBLY................................................ 9-5
9-5.3. PUMP MOTOR SWITCH ADJUSTMENT........ 9-6
9-6. HYDRAULIC PUMP AND MOTOR
ASSEMBLY...................................................... 9-6
9-6.1. PUMP AND MOTOR ASSEMBLY REMOVAL. 9-6
9-6.2. HYDRAULIC PRESSURE ADJUSTMENT. ..... 9-6
9-7. LIFT CYLINDER REPAIR. ............................... 9-7
9-7.1. NON-TELESCOPIC. ........................................ 9-7
9-7.2. TELESCOPIC. ................................................. 9-7
9-7.3. FULL FREE LIFT. .......................................... 9-10
10 ELECTRICAL COMPONENTS ................................. 10-1
10-1. ELECTRICAL CONTROL PANELS. .............. 10-1
10-2. CONTROL PANEL SERVICING.................... 10-1
10-3. CONTACTOR SERVICING.
SERIAL NUMBER 333375 TO 364407.......... 10-3
10-3.1.2ND AND 3RD SPEED CONTACTOR
DISASSEMBLY.
SERIAL NUMBER 333375 TO 364407.......... 10-3
10-3.2.2ND AND 3RD SPEED CONTACTOR
REASSEMBLY.
SERIAL NUMBER 333375 TO 364407.......... 10-3
Figure
1-1 NAME PLATE .................................................... 1-1
1-2 SERIAL NUMBER AND DECAL LOCATION..... 1-3
1-3 PDI LIFT TRUCK ............................................... 1-4
2-1 LOAD CENTER.................................................. 2-1
2-2 SAMPLE OF OPERATOR CHECK LIST ........... 2-4
2-3 CONTROL HANDLE .......................................... 2-5
2-4 STEERING ARM BRAKING POSITION ............ 2-6
2-5 LIFT/LOWER LEVER......................................... 2-7
3-1 REINSTALLING THE BATTERY ....................... 3-2
3-2 CHARGE INDICATOR ....................................... 3-4
3-3 LUBRICATION DIAGRAM ................................. 3-6
4-1 BATTERY CHARGER SCHEMATIC ................. 4-5
4-2 LOGIC BOARD JUMPER POSITION ................ 4-5
4-3 LOGIC FLOW DIAGRAM (SHEET 1) ................ 4-6
4-4 . DIP SWITCH SETTINGS ................................... 4-8
4-5 . BATTERY CHARGER WIRING DIAGRAM ....... 4-9
4-6 WIRING DIAGRAM (SHEET 1)........................ 4-10
4-7 WIRING DIAGRAM (SHEET 1)........................ 4-12
5-1 BELLY-BUTTON SWITCH ADJUSTMENT........ 5-1
5-2 SCHEMATIC OF COLD CONDITIONING
CIRCUIT............................................................. 5-1
5-3 LOCATION OF RESISTORS AND
THERMAL CUTOUT SWITCH........................... 5-2
5-4 CONTROL HEAD ASSEMBLY .......................... 5-3
5-5 PUSH BUTTON SWITCHES ............................. 5-5
5-6 STEERING ARM AND ELECTRICAL CABLE ... 5-7
5-7 PIVOT TUBE ASSEMBLY ................................. 5-8
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TABLE OF CONTENTS (Cont)
Page Section
10-3.3.FORWARD-REVERSE CONTACTOR
10-3.4.FORWARD-REVERSE CONTACTOR
10-4. PUMP MOTORS. ........................................... 10-6
10-5. DRIVE MOTORS............................................ 10-6
10-6. BATTERY CHARGER.................................... 10-6
10-7. BATTERIES. .................................................. 10-8
10-8. FUSE.............................................................. 10-8
10-9. HIGH SPEED LIMIT SWITCH...................... 10-10
10-10. HORN........................................................... 10-10
11 OPTIONAL EQUIPMENT ..........................................11-1
11-1. KEYSWITCH .................................................. 11-1
11-2. HOUR METER ............................................... 11-1
11-3. BATTERY CAPACITY INDICATOR. ..............11-1
11-4. REMOTE CONTROL. ....................................11-1
11-5. REMOTE CONTROL INSTALLATION........... 11-1
11-5.1.PUSHBUTTON BOX REMOTE
11-5.2.CONTROL HEAD LIFT/LOWER .................... 11-1
12 ILLUSTRATED PARTS BREAKDOWN .................... 12-1
LIST OF ILLUSTRATIONS
Page Figure
5-8
5-9
6-1
6-2
6-3
7-1
7-2
7-3
8-1
8-2
8-3
8-4
9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8
9-9
10-1
10-2
DISASSEMBLY.
SERIAL NUMBER 333375 TO 364407 .......... 10-4
REASSEMBLY.
SERIAL NUMBER 333375 TO 364407 .......... 10-5
CONTROL...................................................... 11-1
PIVOT TUBE REMOVAL TOOL......................... 5-9
ELECTRICAL CONTROL CABLE
REPLACEMENT............................................... 5-11
BRAKE ENGAGE/DISENGAGE......................... 6-1
ADJUSTMENT ................................................... 6-2
PARTS REPLACEMENT.................................... 6-3
TRANSMISSION ................................................ 7-2
ADJUSTABLE STRADDLE FRAME................... 7-3
LOAD WHEELS.................................................. 7-4
ELEVATION SYSTEM (TELESCOPIC) ............. 8-1
ELEVATION SYSTEM (TELESCOPIC) ............. 8-2
ELEVATION SYSTEM (NON-TELESCOPIC) .... 8-3
ELEVATION SYSTEM (FULL FREE LIFT) ........ 8-4
HYDRAULIC SYSTEM SCHEMATIC................. 9-1
HYDRAULIC SYSTEM (TELESCOPIC AND
NON-TELESCOPIC) .......................................... 9-2
HYDRAULIC SYSTEM (FULL FREE LIFT)........ 9-3
LIFT/LOWER CONTROL VALVE
ADJUSTMENT ................................................... 9-4
LIFT/LOWER CONTROL VALVE (STANDARD) 9-5
LIFT/LOWER CONTROL VALVE
(COLD CONDITIONING).................................... 9-5
LIFT CYLINDER (NON-TELESCOPIC).............. 9-8
LIFT CYLINDER (TELESCOPIC)....................... 9-9
LIFT CYLINDER (FULL FREE LIFT)................ 9-11
ELECTRICAL CONTROL PANEL .................... 10-1
ELECTRICAL CONTROL PANEL .................... 10-2
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PDI0404