(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.
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. 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. 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 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.)