tw's logo

Contact Us

If you still have questions or prefer to get help directly from an agent, please submit a request.
We’ll get back to you as soon as possible.

Please fill out the contact form below and we will reply as soon as possible.

  • Home
  • Home

(IN PROG.)DP2 Manual: 904160 Model: PDCM Serial Number: 333032 and higher[904160_PDCM_333032]

Learn how to use the DP2 Manual for the 904160 Model PDCM with Serial Numbers 333032 and higher.

Written by Nash Bernardo

Updated at February 20th, 2025

Contact Us

If you still have questions or prefer to get help directly from an agent, please submit a request.
We’ll get back to you as soon as possible.

Please fill out the contact form below and we will reply as soon as possible.

+ More


Manual: 904160
Model: PDCM
Serial Number: 333032 and higher

This manual is affected by the following supplements. They can be found in the Service Manual Index CD on the left side of the screen under "Supplements To Manuals."
 

SUPPLEMENT 

TITLE 

207 

TRANSISTOR CONTROL HEAD 

220 A 

TRANSISTOR CONTROL HEAD 

229 

005467-02 PDCM 

245 

BATTERY SAFETY AND MAINTENANCE 

283 

PDCM TRUCK MODEL PDCM-25-130 

318 

CONTROL ARM ASSEMBLY 

346 

PDCM TRANS/CONTROLLER/CONTACTOR TYPE E AND EE 

356 

CYLINDER 503568 PACKING CHANGE 


Manual Price $35.00

PDCM SERIES
POWER DRIVE COUNTERBALANCED
LIFT TRUCK
Serial Number 333032 and Higher

Operation
Maintenance
Repair Parts List

 

 

 

 

 

 

 

 

Big Joe Manufacturing Company − Lincolnwood, IL 60646                                                                            MANUAL NO. 904160
                                                                                                                                                                                               REV A 1/18/02


WARNING

Do not operate this truck unless you have been trained and authorized to do so, and have read all warnings and instructions in operator's manual on this truck.

Do not operate this truck until you have checked its condition. Give special attention to tires, horn, lights, battery, controller, lift system (including forks or attachments, chains, cables and limit switches), brakes, steering mechanism, guards and safety devices.

Operate truck only from designated operating position. Never place any part of your body into the mast structure or between the mast and the truck. Do not carry passengers.
Observe applicable traffic regulations. Yield right of way to pedestrians. Slow down and sound horn at cross aisles and wherever vision is obstructed.
Start, stop, travel, steer and brake smoothly. Slow down for turns and on uneven or slippery surface that could cause truck to slide or overturn. Use special care when travelling without load as the risk of overturn may be greater.

Travel with lifting mechanism as low as possible. Always look in direction of travel. Keep a clear view, and when load interferes with visibility, travel with load or lifting mechanism trailing.
Use special care when operating on ramps—travel slowly, and do not angle or turn. Travel with lifting mechanism downhill.
Do not overload truck. Check capacity plate for load weight and load center information.

When using forks, space forks as far apart as load will permit. Before lifting, be sure load is centered, forks are completely under load, and load is as far back as possible against load backrest.
Do not handle unstable or loosely stacked loads. Use special care when handling long, high or wide loads to avoid losing the load, striking bystanders, or tipping the truck.

Do not handle unstable loads which are higher than the load backrest or load backrest extension. unless load is secured so that no part of it could fall backward.

Elevate forks of lifting mechanism only to pick up or stack a load watch out for obstructions, especially overhead.

Do not lift except on securely attached specially designed work platform. Use extreme care when lifting personnel. Make sure mast is vertical, place truck controls in neutral and apply brakes. Lift and lower smoothly. Remain in operating position or immediate vicinity as long as personnel are one the work platform. Never transport personnel on forks or work platform.

Do not allow anyone to stand or pass under load or lifting mechanism.

When leaving truck, neutralize travel control fully lower lifting mechanism and set brake. When leaving truck unattended, also shut off power


TABLE OF CONTENTS

Section 

Page 

OPERATOR INSTRUCTIONS 

Warning 

v 

Preparation 

v 

               1                  DESCRIPTION 

1-1 

Introduction 

1-1 

1-2 

General Description 

1-1 

1-3 

Safety Features 

1-2 

1-4 

Options and Accessories 

1-2 

2 

OPERATION 

2-1 

General 

2-1 

2-2 

Operating Precaution 

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 Control 

2-5 

2-4.3 

Battery Disconnect 

2-5 

2-4.4 

Optional Features 

2-5 

2-5 

Operation 

2-6 

2-5.1 

Foward and Reverse Travel and Speed control 

2-6 

2-5.2 

Steering 

2-6 

2-5.3 

Stopping 

2-6 

2-5.4 

Parking 

2-7 

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 

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 

3-2 

3-3.3 

Charger Operation 

3-2 

3-4 

Lubrication 

3-2 

4 

TROUBLESHOOTING 

4-1 

General 

4-1 

5 

STEERING ARM AND CONTROL HEAD SERVICING 

5-1 

General 

5-1 

5-2 

Belly-Button Switch Adjustment 

5-1 

5-3 

Control Head Switch Replacement 

5-2 

5-4 

Speed Control Switch Return Spring Replacement 

5-4 

5-5 

Steering Arm Return Spring Adjustment 

5-4 

5-6 

Steering Arm Return Spring Replacement 

5-6 

5-7 

Pivot Tube Replacement 

5-7 

5-8 

Electrical Control Cable Replacement 

5-8 

5-9 

Steering Arm and Pivot Cap Replacement 

5-10 

6 

BRAKE SERVICING 

6-1 

General 

6-1 

6-2 

Adjustment 

6-1 

6-2.1 

Adjustment for Truck Serial Numbers 333756 and Higher 

6-2 

6-2.2 

Adjustment for Truck Serial Numbers 333032 to 333756 

6-2 

6-3 

Replacement of Disc Brake Parts 

6-3 

6-3.1 

Parts Replacement for Trucks Serial Number 333756 and Higher 

6-3 

6-3.2 

Part Replacement for truck Serial Number 333032 to 333756 

6-4 

6-4 

Brake Lever Replacement 

6-5 

7 

TRANSMISSION SERVICING 

7-1 

Transmission Replacement 

7-1 

7-2 

Drive Wheel Replacement 

7-1 

7-3 

Load Wheel Replacement 

7-1 

8 

ELEVATION SYSTEM SERVICING 

8-1 

General 

8-1 

8-2 

Ram Head Removal 

8-1 

8-3 

Lift Chain Adjustment 

8-1 

8-4 

Lift Chain Replacement 

8-1 

8-5 

Lift Cylinder Removal 

8-1 

8-6 

Mast Removal 

8-2 

8-7 

Lift Carriage Replacement 

8-2 


TABLE OF CONTENTS (CONT.)

 

 

 


 

development work in progress

Was this article helpful?

Yes
No
Give feedback about this article

Related Articles

© 2021 Total Warehouse | All Rights Reserved.

  • Follow Us
Expand