Manual Price $35.

00

PDI SERIES
POWER DRIVE INTERMEDIATE
LIFT TRUCK
Serial Number 333375 to 376499
Operation
Maintenance
Repair Parts List

Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901355
REV. B 0404
 TABLE OF CONTENTS

Section Page Section Page

1 DESCRIPTION ............................................................1-1 5-5. SPEED CONTROL SWITCH RETURN
1-1. INTRODUCTION. .............................................1-1 SPRING REPLACEMENT. .............................. 5-4
1-2. GENERAL DESCRIPTION...............................1-1 5-6. STEERING ARM RETURN SPRING
1-3. SAFETY FEATURES. ......................................1-2 ADJUSTMENT................................................. 5-6
1-4. OPTIONS AND ACCESSORIES......................1-2 5-7. STEERING ARM RETURN SPRING
REPLACEMENT. ............................................. 5-6
2 OPERATION ...............................................................2-1 5-8. PIVOT TUBE FLANGED BUSHING
2-1. GENERAL. .......................................................2-1 REPLACEMENT. ............................................. 5-8
2-2. OPERATING PRECAUTIONS. ........................2-1 5-9. ELECTRICAL CONTROL CABLE
2-3. BEFORE OPERATION.....................................2-2 REPLACEMENT. ........................................... 5-10
2-4. POWER DRIVE CONTROL HANDLE..............2-5
2-4.1. CONTROL HANDLE. .......................................2-5 6 BRAKE SERVICING ................................................... 6-1
2-4.2. STEERING ARM CONTROLS. ........................2-5 6-1. ADJUSTMENT................................................. 6-1
2-5. DRIVING AND STOPPING PROCEDURES. ...2-5 6-2. REPLACEMENT OF DISC BRAKE PARTS .... 6-2
2-6. BELLY-BUTTON SWITCH GUARD. ................2-6
2-7. STEERING ARM RETURN SPRING. ..............2-6 7 TRANSMISSION, DRIVE WHEEL,
2-8. LIFT/LOWER CONTROL. ................................2-6 ADJUSTABLE STRADDLE,AND LOAD
2-9. LOADING AND UNLOADING. .........................2-7 WHEEL SERVICING .................................................. 7-1
2-10. PARKING. .......................................................2-7 7-1. INITIAL DISASSEMBLY .................................. 7-1
7-2. DRIVE AXLE AND WHEEL REMOVAL........... 7-1
3 PLANNED MAINTENANCE ........................................3-1 7-3. REMOVAL OF MOTOR AND BRAKE
3-1. GENERAL. .......................................................3-1 ASSEMBLY INCLUDING DRIVE GEAR.......... 7-1
3-2. MONTHLY AND QUARTERLY CHECKS. .......3-1 7-4. REMOVAL OF BRAKE DISC ASSEMBLY. ..... 7-1
3-3. WET CELL BATTERY CARE. ..........................3-1 7-5. ADJUSTABLE STRADDLE LIFT TRUCKS ..... 7-3
3-3.1. GENERAL. .......................................................3-1 7-6. LOAD WHEELS. .............................................. 7-4
3-3.2. TIMER CHARGER OPERATION. ....................3-2
3-3.3. SMART CHARGER OPERATION....................3-3 8 ELEVATION SYSTEM SERVICING ........................... 8-1
3-4. GEL CELL BATTERY CARE (OPTIONAL) ......3-3 8-1. GENERAL........................................................ 8-1
3-4.1. GENERAL. .......................................................3-3 8-2. LIFT CHAIN LENGTH ADJUSTMENT............. 8-1
3-4.2. CHARGING BATTERIES .................................3-3 8-2.1. TELESCOPIC AND NON-TELESCOPIC......... 8-1
3-4.3. REMOVING BATTERIES FROM CHARGER ..3-4 8-2.2. FULL FREE LIFT. ............................................ 8-2
3-5. LUBRICATION. ................................................3-5 8-3. LIFT CHAIN WEAR INSPECTION................... 8-2
3-6. LIFT CHAIN MAINTENANCE...........................3-5 8-4. LIFT CHAIN REPLACEMENT. ........................ 8-3
8-4.1. TELESCOPIC AND NON-TELESCOPIC......... 8-3
4 TROUBLESHOOTING ................................................4-1 8-4.2. FULL FREE LIFT. ............................................ 8-5
4-1. GENERAL ........................................................4-1 8-5. LIFT CYLINDER REMOVAL............................ 8-5
4-2. SMART CHARGER 004978 8-5.1. NON-TELESCOPIC. ........................................ 8-5
TROUBLESHOOTING ....................................4-5 8-5.2. TELESCOPIC. ................................................. 8-5
4-3. OPTIONAL GEL CELL BATTERY 8-5.3. FULL FREE LIFT. ............................................ 8-6
CHARGER 004987 TROUBLESHOOTING .....4-8 8-6. RAM HEAD REMOVAL. .................................. 8-6
4-3.1. DIP SWITCH SETTING ...................................4-8 8-6.1. NON-TELESCOPIC. ........................................ 8-6
4-3.2. THERMISTOR..................................................4-8 8-6.2. TELESCOPIC. ................................................. 8-6
4-3.3. CIRCUIT BREAKER TESTING ........................4-8 8-7. YOKE SHEAVE REPLACEMENT
4-3.4. POWER TRANSFORMER TESTING...............4-8 (FULL FREE LIFT)........................................... 8-7
4-3.5. CIRCUIT BOARD TESTING.............................4-8 8-8. LUBRICATION OF MAST................................ 8-7
5 STEERING ARM AND CONTROL HEADS 9 HYDRAULIC SYSTEM SERVICING........................... 9-1
SERVICING.................................................................5-1 9-1. RELIEVING SYSTEM PRESSURE. ................ 9-1
5-1. GENERAL. .......................................................5-1 9-2. FLOW CONTROL VALVE
5-2. COLD CONDITIONING. ...................................5-1 REPLACEMENT .............................................. 9-1
5-3. BELLY-BUTTON SWITCH ADJUSTMENT ......5-2 9-3. SUCTION LINE FILTER REPLACEMENT. ..... 9-2
5-4. CONTROL HEAD SWITCH 9-4. LINE OR FITTING REPLACEMENT................ 9-4
REPLACEMENT...............................................5-4

PDI0404 i
 TABLE OF CONTENTS (Cont)

Section Page Section Page

9-5. LIFT/LOWER CONTROL VALVE. ................... 9-4 10-3.3.FORWARD-REVERSE CONTACTOR
9-5.1. ADJUSTMENT................................................. 9-4 DISASSEMBLY.
9-5.2. DISASSEMBLY................................................ 9-5 SERIAL NUMBER 333375 TO 364407 .......... 10-4
9-5.3. PUMP MOTOR SWITCH ADJUSTMENT........ 9-6 10-3.4.FORWARD-REVERSE CONTACTOR
9-6. HYDRAULIC PUMP AND MOTOR REASSEMBLY.
ASSEMBLY...................................................... 9-6 SERIAL NUMBER 333375 TO 364407 .......... 10-5
9-6.1. PUMP AND MOTOR ASSEMBLY REMOVAL. 9-6 10-4. PUMP MOTORS. ........................................... 10-6
9-6.2. HYDRAULIC PRESSURE ADJUSTMENT. ..... 9-6 10-5. DRIVE MOTORS............................................ 10-6
9-7. LIFT CYLINDER REPAIR. ............................... 9-7 10-6. BATTERY CHARGER.................................... 10-6
9-7.1. NON-TELESCOPIC. ........................................ 9-7 10-7. BATTERIES. .................................................. 10-8
9-7.2. TELESCOPIC. ................................................. 9-7 10-8. FUSE.............................................................. 10-8
9-7.3. FULL FREE LIFT. .......................................... 9-10 10-9. HIGH SPEED LIMIT SWITCH...................... 10-10
10-10. HORN........................................................... 10-10
10 ELECTRICAL COMPONENTS ................................. 10-1
10-1. ELECTRICAL CONTROL PANELS. .............. 10-1 11 OPTIONAL EQUIPMENT ..........................................11-1
10-2. CONTROL PANEL SERVICING.................... 10-1 11-1. KEYSWITCH .................................................. 11-1
10-3. CONTACTOR SERVICING. 11-2. HOUR METER ............................................... 11-1
SERIAL NUMBER 333375 TO 364407.......... 10-3 11-3. BATTERY CAPACITY INDICATOR. ..............11-1
10-3.1.2ND AND 3RD SPEED CONTACTOR 11-4. REMOTE CONTROL. ....................................11-1
DISASSEMBLY. 11-5. REMOTE CONTROL INSTALLATION........... 11-1
SERIAL NUMBER 333375 TO 364407.......... 10-3 11-5.1.PUSHBUTTON BOX REMOTE
10-3.2.2ND AND 3RD SPEED CONTACTOR CONTROL...................................................... 11-1
REASSEMBLY. 11-5.2.CONTROL HEAD LIFT/LOWER .................... 11-1
SERIAL NUMBER 333375 TO 364407.......... 10-3
12 ILLUSTRATED PARTS BREAKDOWN .................... 12-1

LIST OF ILLUSTRATIONS

Figure Page Figure Page

1-1 NAME PLATE .................................................... 1-1 5-8 PIVOT TUBE REMOVAL TOOL......................... 5-9
1-2 SERIAL NUMBER AND DECAL LOCATION..... 1-3 5-9 ELECTRICAL CONTROL CABLE
1-3 PDI LIFT TRUCK ............................................... 1-4 REPLACEMENT............................................... 5-11
2-1 LOAD CENTER.................................................. 2-1 6-1 BRAKE ENGAGE/DISENGAGE......................... 6-1
2-2 SAMPLE OF OPERATOR CHECK LIST ........... 2-4 6-2 ADJUSTMENT ................................................... 6-2
2-3 CONTROL HANDLE .......................................... 2-5 6-3 PARTS REPLACEMENT.................................... 6-3
2-4 STEERING ARM BRAKING POSITION ............ 2-6 7-1 TRANSMISSION ................................................ 7-2
2-5 LIFT/LOWER LEVER......................................... 2-7 7-2 ADJUSTABLE STRADDLE FRAME................... 7-3
3-1 REINSTALLING THE BATTERY ....................... 3-2 7-3 LOAD WHEELS.................................................. 7-4
3-2 CHARGE INDICATOR ....................................... 3-4 8-1 ELEVATION SYSTEM (TELESCOPIC) ............. 8-1
3-3 LUBRICATION DIAGRAM ................................. 3-6 8-2 ELEVATION SYSTEM (TELESCOPIC) ............. 8-2
4-1 BATTERY CHARGER SCHEMATIC ................. 4-5 8-3 ELEVATION SYSTEM (NON-TELESCOPIC) .... 8-3
4-2 LOGIC BOARD JUMPER POSITION ................ 4-5 8-4 ELEVATION SYSTEM (FULL FREE LIFT) ........ 8-4
4-3 LOGIC FLOW DIAGRAM (SHEET 1) ................ 4-6 9-1 HYDRAULIC SYSTEM SCHEMATIC................. 9-1
4-4 . DIP SWITCH SETTINGS ................................... 4-8 9-2 HYDRAULIC SYSTEM (TELESCOPIC AND
4-5 . BATTERY CHARGER WIRING DIAGRAM ....... 4-9 NON-TELESCOPIC) .......................................... 9-2
4-6 WIRING DIAGRAM (SHEET 1)........................ 4-10 9-3 HYDRAULIC SYSTEM (FULL FREE LIFT)........ 9-3
4-7 WIRING DIAGRAM (SHEET 1)........................ 4-12 9-4 LIFT/LOWER CONTROL VALVE
5-1 BELLY-BUTTON SWITCH ADJUSTMENT........ 5-1 ADJUSTMENT ................................................... 9-4
5-2 SCHEMATIC OF COLD CONDITIONING 9-5 LIFT/LOWER CONTROL VALVE (STANDARD) 9-5
CIRCUIT............................................................. 5-1 9-6 LIFT/LOWER CONTROL VALVE
5-3 LOCATION OF RESISTORS AND (COLD CONDITIONING).................................... 9-5
THERMAL CUTOUT SWITCH........................... 5-2 9-7 LIFT CYLINDER (NON-TELESCOPIC).............. 9-8
5-4 CONTROL HEAD ASSEMBLY .......................... 5-3 9-8 LIFT CYLINDER (TELESCOPIC)....................... 9-9
5-5 PUSH BUTTON SWITCHES ............................. 5-5 9-9 LIFT CYLINDER (FULL FREE LIFT)................ 9-11
5-6 STEERING ARM AND ELECTRICAL CABLE ... 5-7 10-1 ELECTRICAL CONTROL PANEL .................... 10-1
5-7 PIVOT TUBE ASSEMBLY ................................. 5-8 10-2 ELECTRICAL CONTROL PANEL .................... 10-2

ii PDI0404
 LIST OF ILLUSTRATIONS (Cont)

Figure Page Figure Page

10-3 CONTACTOR (2ND AND 3RD SPEED) 12-23 LIFT CYLINDERS (FULL FREE LIFT)........... 12-36
PART NUMBER 005659 ..................................10-4 12-24 LIFT CONTROL VALVE (STANDARD) ......... 12-38
10-4 CONTACTOR (FORWARD-REVERSE) 12-25 LIFT CONTROL VALVE
PART NUMBER 005657 ..................................10-5 (COLD CONDITIONING) ............................... 12-38
10-5 BATTERY CHARGER 004967-01 AND 12-26 BATTERIES ................................................... 12-40
004967-02 SCHEMATIC ..................................10-6 12-27 QUICK DISCONNECT CABLE
10-6 BATTERY CHARGER 004976-01 INSTALLATION ............................................. 12-42
SCHEMATIC ....................................................10-7 12-28 ELECTRICAL COMPONENTS ...................... 12-44
10-7 BATTERY CHARGER 004978 SCHEMATIC ...10-7 12-29 HYDRAULIC PUMP AND MOTOR 905046... 12-46
10-8 BASE, FRAME AND ELECTRICAL 12-30 HYDRAULIC PUMP AND MOTOR
COMPONENTS ................................................10-9 ASSEMBLY 016935....................................... 12-47
10-9 ELECTRICAL COMPONENTS.......................10-10 12-31 HYDRAULIC PUMP AND MOTOR
12-1 CONTROL HEAD ASSEMBLY.........................12-2 ASSEMBLY 016942....................................... 12-48
12-2 PUSH BUTTON SWITCHES, CONTROL 12-32 HYDRAULIC PUMP AND MOTOR
HEAD................................................................12-4 ASSEMBLY 016940....................................... 12-49
12-3 COLD CONDITIONING, CONTROL HEAD......12-5 12-33 ELECTRICAL CONTROL PANEL ................. 12-50
12-4 STEERING ARM AND ELECTRICAL CABLE..12-6 12-34 ELECTRICAL CONTROL PANEL ................. 12-51
12-5 PIVOT TUBE ASSEMBLY ................................12-8 12-35 CONTACTOR (2ND AND 3RD SPEED)........ 12-52
12-6 BRAKE AND LINKAGE ..................................12-10 12-36 CONTACTOR (FORWARD/REVERSE) ........ 12-52
12-7 TRANSMISSION ............................................12-12 12-37 "SMART" BATTERY CHARGER
12-8 DRIVE MOTOR 016046 .................................12-14 INSTALLATION ............................................. 12-53
12-9 DRIVE MOTOR 016052 .................................12-15 12-38 GEL CELL BATTERY CHARGER ................. 12-54
12-10 BASE AND FRAME ........................................12-16 12-39 BATTERY CHARGER MOUNTING ............... 12-55
12-11 DECAL LOCATION ........................................12-18 12-40 OPTIONAL "SMART" CHARGER 004976-01
12-12 ADJUSTABLE STRADDLE FRAME...............12-19 (REPLACES TIMER CHARGER 004967-01) 12-56
12-13 LOAD WHEELS..............................................12-19 12-41 STANDARD TIMER BATTERY CHARGER
12-14 ELEVATION SYSTEM (TELESCOPIC)..........12-20 004967-01 AND 004967-02 ........................... 12-57
12-15 ELEVATION SYSTEM (TELESCOPIC)..........12-22 12-42 OPTIONAL KEYSWITCH .............................. 12-58
12-16 ELEVATION SYSTEM (NON-TELESCOPIC) 12-24 12-43 OPTIONAL HOUR METER............................ 12-58
12-17 ELEVATION SYSTEM (FULL FREE LIFT).....12-26 12-44 OPTIONAL BATTERY CAPACITOR
12-18 LIFT CARRIAGE AND FORKS.......................12-28 INDICATOR ................................................... 12-59
12-19 HYDRAULIC SYSTEM (TELESCOPIC AND 12-45 OPTIONAL BATTERY CAPACITOR
NON-TELESCOPIC).......................................12-30 INDICATOR ................................................... 12-60
12-20 HYDRAULIC SYSTEM (FULL FREE LIFT) ....12-31 12-46 OPTIONAL REMOTE CONTROL
12-21 LIFT CYLINDER (NON-TELESCOPIC)..........12-32 INSTALLATION ............................................. 12-61
12-22 LIFT CYLINDER (TELESCOPIC) ....................12-34

LIST OF TABLES (Cont)

Table Page Table Page

2-1 OPERATOR CHECKS .........................................2-2 3-3 RECOMMENDED LUBRICANTS ........................ 3-5
3-1 MONTHLY AND QUARTERLY 3-4 LUBRICATION CHART ....................................... 3-6
INSPECTION AND SERVICE CHART.................3-1 4-1 TROUBLESHOOTING CHART ............................ 4-1
3-2 CHARGER TIME FOR BATTERY CHARGING ...3-3 10-1 BATTERY CHARGERS ..................................... 10-6

PDI0404 iii
 OPERATOR INSTRUCTIONS

WARNING

Do not operate this truck unless you have been trained Do not overload truck. Check capacity plate for load
and authorized to do so and have read all warnings weight and load center information.
and instructions in operator's manual and on this truck. When using forks, space forks as far apart as load will
Do not operate this truck until you have checked its permit. Before lifting, be sure load is centered, forks
condition. Give special attention to Tires, Horn, Lights, are completely under load, and load is far back as pos-
Battery, Controller, Lift System, (including forks or sible against load backrest.
attachments, chains, cables and limit switches),
Do not handle unstable or loosely stacked loads. Use
Brakes, Steering Mechanism, Guards and Safety
special care when handling long, high or wide loads to
Devices.
avoid losing the load, striking bystanders, or tipping
Operate truck only from designated operating position. the truck.
Never place any part of your body into the mast struc-
Do not handle loads which are higher than the load
ture or between the mast and the truck. Do not carry
backrest or load backrest extension unless load is
passengers. Keep feet clear of truck.
secured so that no part of it could fall backward.
Observe applicable traffic regulations. Yield right of
Elevate forks or other lifting mechanism only to pick up
way to pedestrians. Slow down and sound horn at
or stack a load. Watch out for obstructions, especially
cross aisles and wherever vision is obstructed.
overhead.
Start, stop, travel, steer and brake smoothly. Slow Do not lift personnel except on a securely attached
down for turns and on uneven or slippery surfaces that specially designed Work Platform. Use extreme care
could cause truck to slide or overturn. Use special when lifting personnel. Make sure mast is vertical,
care when traveling without load as the risk of overturn place truck controls in neutral and apply brakes. Lift
may be greater. and lower smoothly. Remain in operating position or
Travel with lifting mechanism as low as possible. immediate vicinity as long as personnel are on the
Always look in direction of travel. Keep a clear view, Work Platform. Never transport personnel on forks or
and when load interferes with visibility, travel with load Work Platform.
or lifting mechanism trailing, except when traveling
Do not allow anyone to stand or pass under load or lift-
downhill.
ing mechanism.
Use special care when operating on ramps—travel
When leaving truck, neutralize travel control. Fully
slowly, and do not angle or turn. Travel with lifting
lower lifting mechanism and set brake. When leaving
mechanism or load downhill.
truck unattended, also shut off power.

PREPARATION FOR USE

Upon receipt, visually inspect the truck. If any damage If you did not order an optional charge cord (Fig-
is found, report it to the carrier and to your Big Joe ure 12-38 or Figure 12-39) then purchase an exten-
dealer immediately. sion cord, 16 gauge, 3 wire, UL approved of the
type normally used for shop tools, heavier appli-
Remove cardboard banded to forks. Check lift truck for
ances, etc.
scratches and dents. Check to make sure that the lift
chains are free of slack. Inspect for oil leaks and loose Refer to Section 2 for operating instructions to test the
wiring connections. Make certain that all accessories brakes and lift control.
and attachments that were ordered are supplied.
If you do not obtain the proper results, or if improper
Before the lift truck is moved, the battery must be operation occurs, refer to troubleshooting in SECTION
checked, recharged if necessary, and connected. 4.
Refer to “Battery Care” in SECTION 3 for battery
checking instructions.

iv PDI0404
 SECTION 1
DESCRIPTION

1-1. INTRODUCTION.
This publication describes the Power Drive Intermedi-
ate (PDI) lift truck manufactured by Big Joe Manufac-
turing Company, Des Plaines, Illinois, 60018. Included
are operating instructions, planned maintenance
instructions, lubrication procedures, corrective mainte-
nance procedures and a complete parts list with parts
location illustrations.
Users shall comply with all requirements indicated in
applicable OSHA standards and current edition of
A.N.S.I. B56.1 Part II. By following these requirements
and the recommendations contained in this manual,
you will receive many years of dependable service
from your Big Joe lift truck.
The lift truck is identified by a model number. The
model number shows truck capacity and load center. A
typical model number is explained below.

R6209

Figure 1-1 Name Plate

The model number will be found on the (Figure 1-1)
along with the serial number, lifting capacity, and load
center. Figure 1-3 shows the locations of the trucks
main components and controls. Figure 1-2 shows the
location and identification of the decals. Also listed is
the touchup paint used on both the older and new
model PDI trucks as well as the location of the trucks
serial number and name plate.

1-2. GENERAL DESCRIPTION.

The self-propelled PDI truck, Figure 1-3, lifts and
transports payloads up to 2000 pounds on either rigid
or adjustable forks.
The forward and reverse motion is controlled by the
speed controller switch in the control head. Stopping
and turning is controlled by the steering arm. Lift and
Lower is controlled by either a lever mounted on the
chassis, optional pushbutton controls located on the
steering arm, or a control box attached by a coiled
cord.

PDI0404 1-1
The battery-powered lift truck is quiet and without 1-4. OPTIONS AND ACCESSORIES.
exhaust fumes.
Big Joe offers many options and accessories for the
The reversible dc motor propels the lift truck in forward PDI lift truck such as:
and reverse direction throughout the available speed
Key switch
range. The PDI lift truck can be driven with forks raised
Remote Lift/Lower Control in Control Arm or Remote
or lowered; however, the speed is restricted when the
Control Box Attached by a Coiled Cord or both
forks are raised above a preset limit.
Wider Lift Carriage
Cold Conditioning
1-3. SAFETY FEATURES.
Battery Capacity Indicator with or without Lift Lockout
The PDI is designed and engineered to provide maxi- Hour Meter For Motors
mum safety for operator and payload. Some of the Longer Carriage Forks
safety features incorporated into the design are: Dry Charged Batteries
Dead-man brake to apply mechanical brake and cut off 240 V, 60 Hz, Single Phase Charger
48 inch Load Backrest Extension
drive power when the steering arm is released.
Adjustable Straddles
Belly-button switch to reverse truck should the opera- RAMS
tor accidentally pin himself against a wall or obstruc- Boom w/Hook
tion when backing up. Slip-on Platform...smooth or diamond surface
High speed limit switch to restrict speed when lift car- Roller Platform
riage is raised above the preset limit. Work Platform
Transistor Control
All control functions automatically return to “OFF”
when released. The most commonly used options and accessories are
described in SECTION 11.
Externally accessible quick-disconnect battery plug
within operator's reach.
Separately fused control circuits and power circuits.
Readily accessible HORN button.
Lift carriage backrest to help stabilize the load.
Pressure compensated flow control valve regulates
maximum lowering speed within prescribed limits.
High visibility color scheme of truck provides visual
alert of trucks presence.

1-2 PDI0404
 R5801

Figure 1-2 Serial Number and Decal Location

TOUCH-UP PAINT 905001 DECAL KIT

901201 YELLOW PART NO. DESCRIPTION QTY.
901202 BLACK 056478 LIFT-LOWER 1
056499 NO RIDING 1
056564 CAUTION 2
056494 CAUTION 2
056610 WARNING 1
056625 WARNING 1
056626 OIL LEVEL 1
056632 BIG JOE (MAST) 2
056644 TRUCK-CHARGE 1
056646 DANGER-BATTERY 1
056648 INSTR-CHARGER 1

PDI0404 1-3
 R3813

Figure 1-3 PDI Lift Truck

1-4 PDI0404
 SECTION 2
OPERATION

1. Do not operate this truck unless you have been

1. SEE SUPPLEMENT 207 FOR TRANSISTOR trained and authorized to do so. Read all warn-
CONTROL HEAD USED ON TRUCKS SERIAL ings and instructions in this manual and on the lift
NUMBER 333375 TO 334630 truck.
2. SEE SUPPLEMENT 220 FOR TRANSISTOR 2. Do not operate this truck until the periodic inspec-
CONTROL HEAD USED ON TRUCKS SERIAL tion or service has been completed.
NUMBER 334631 TO 376499 3. Do not exceed the rated capacity (see name
3. SEE SUPPLEMENT 187 FOR TRANSISTOR plate). Overloading may result in damage to the
CONTROLLER USED ON TRUCKS SERIAL hydraulic system and structural components.
NUMBER 333375 TO 338589 4. Do not handle unstable or loosely stacked loads.
Use special care when handling long, high, or
4. SEE SUPPLEMENT 233 FOR TRANSISTOR
wide loads to avoid tipping, loss of load, or striking
CONTROLLER USED ON TRUCKS SERIAL
bystanders.
NUMBER 338590 TO 372811
5. Center and carry the load as far back as possible
5. SEE SUPPLEMENT 349 FOR TRANSISTOR
toward the lift carriage back rest. Do not pick up
CONTROLLER USED ON TRUCKS SERIAL
loads on the tips of forks. The center-of-gravity of
NUMBER 372812 TO 376499
the load must not exceed the load center listed on
the name plate. See Figure 2-1 for load center
2-1. GENERAL. limitations.
6. Pick up loads on both forks. Do not pick up loads
This section gives detailed operating instructions for
on only one fork.
the PDI lift truck. The instructions are divided into the
various phases of operations, such as operating the 7. When traveling, always lower the load as far as
lift, driving, and stopping. Routine precautions are possible.
included for safe operation. 8. When stacking pallets in racks and it is necessary
to move the load in the raised position, use cau-
2-2. OPERATING PRECAUTIONS. tion. Operate truck smoothly.
WARNING: Improper operation of the lift truck may 9. Check for obstructions when raising or lowering
result in operator injury, or load and/or lift the lift carriage.
truck damage. Observe the following 10. Apply the brake gently except in cases of emer-
precautions when operating the PDI lift gency.
truck.

R3814

Figure 2-1 Load Center

PDI0404 2-1
11. Observe applicable traffic regulations. Yield right WARNING: Periodic maintenance of this truck by a
of way to pedestrians. Slow down and sound horn QUALIFIED TECHNICIAN is required.
at cross aisles and wherever vision is obstructed.
CAUTION: A QUALIFIED SERVICE TECHNICIAN
12. Operate truck only from designated operating should check the truck monthly for
position. Never place any part of your body proper lubrication, proper fluid levels,
between the mast uprights. Do not carry passen- brake maintenance, motor maintenance
gers. and other areas specified in the SEC-
13. Do not allow anyone to stand or pass under load TION 3.
or lifting mechanism.
WARNING: If the truck is found to be unsafe and in
2-3. BEFORE OPERATION need of repair, or contributes to an
unsafe condition, report it immediately to
Table 2-1 covers important inspection points on PDI lift the designated authority. Do not operate
truck which should be checked prior to operation. it until it has been restored to a safe
Depending on use, some trucks may require additional operating condition. Do not make any
checks. unauthorized repairs or adjustments. All
Figure 2-2 shows a sample format for a Operator service must be performed by a qualified
Checklist, which can be modified as necessary to fit maintenance technician.
your operation.
Table 2-1 Operator Checks

ITEM PROCEDURE ITEM PROCEDURE

Transmission and Check for signs of fluid leakage. Hydraulic Check operation of lift and lower
hydraulic sys- controls to their maximum positions.
tems. Brakes Check that brakes actuate when
Forks Check for cracks and damage; steering arm is raised to upright
and, that they are properly position, and when lowered to
secured. horizontal position. Check that
Chains, cables Check that they are in place, dynamic brake (if so equipped)
and hoses secured correctly, functioning actuates when dynamic brake
properly and free of binding or pushbutton on control handle is
damage. pressed.
Guards and load Check that safety guards are in Deadman/ Check that steering arm raises to
backrest place, properly secured and not Parking brake upright position when released
damaged. and brake applies.
Safety signs Check that warning labels, Battery discon- Check that battery can be
nameplate, etc., are in good nect disconnected and recon-
condition and legible. nected. Check for connector
damage.
Horn Check that horn sounds when
operated. Battery charge Check that battery capacity
meter (if equipped) is on “F”.
Steering Check for binding or looseness in
steering arm when steering. High speed limit Allow for enough space to oper-
switch ate truck in high speed. Elevate
Travel controls Check that speed controls on
forks approximately two feet,
control handle operate in all
then test drive truck to check if
speed ranges in forward and
high speed is cut out.
reverse and that belly button
switch functions.
Wheels Check drive wheel for cracks or
damage. Move truck to check
load and caster wheels for free-
dom of rotation.

2-2 PDI0404
 R5699

Figure 2-2 Sample of Operator Check List

PDI0404 2-3
2-4. POWER DRIVE CONTROL HANDLE. speed in the forward direction. Pressing the speed
control farther closes a contact for second speed and
2-4.1. Control Handle. farther, third speed. Pressing the upper portion of the
Two triangular shaped speed controls provide for easy speed control governs the three reverse speeds in the
thumb actuation. Standard controls include three for- same manner.
ward and three reverse speeds, a belly-button revers- When the rotating grips are utilized, forward direction
ing switch, and a horn. See Figure 2-3. is achieved by rotating the grips downward. Reverse
direction is achieved by rotating the grips upward. Fur-
2-4.2. Steering Arm Controls.
ther rotation in either direction will actuate second and
Lowering the steering arm to the horizontal or raising third speeds in forward or reverse.
to the vertical applies the brake (See Figure 2-4). All
traction control power is shut off when the brake is 2-5. Driving and Stopping Procedures.
engaged. When the steering arm is in the upright posi-
The following procedure describes driving and stop-
tion, the brake acts as a parking brake. Deadman
ping the PDI lift truck. If the lift truck is equipped with a
braking occurs when the handle is released and spring
key switch, turn it to the on position.
action raises it to the vertical position.
1. Grasp the grips of the steering arm so that the
Optional are Lift and Lower pushbuttons. The Lift and
speed control can be comfortably operated by
Lower pushbuttons are located behind the belly-button
either the thumbs, or the palms of the hands if
switch guard and can also be operated from either
rotating grips are being utilized.
side. Also optional is a Lift and Lower remote control
box. 2. Lower the steering arm to a comfortable position
above horizontal to disengage the brake and to
When the lower portion of the triangular speed control
energize the electrical circuits.
knob is pressed forward, contacts are closed for first

1. SEE SUPPLEMENT 207 FOR

TRANSISTOR CONTROL HEAD
USED ON TRUCKS SERIAL
NUMBER 333375 TO 334630
2. SEE SUPPLEMENT 220 FOR
TRANSISTOR CONTROL HEAD
USED ON TRUCKS SERIAL
NUMBER 33461 TO 376499

R3815

Figure 2-3 Control Handle

2-4 PDI0404
 R3629

Figure 2-4 Steering Arm Braking Position

3. To move forward, slowly press the lower portion of the direction of the lift truck to forward direction in low
the speed control or rotate the grips downward. speed.
Press the forward speed control or rotate the grips
farther to increase speed. 2-7. STEERING ARM RETURN SPRING.
4. To stop, release the speed control and lower the The steering arm return spring automatically raises
steering arm to the horizontal position. In this the steering arm to the upright position when the
position, the brake pads apply light pressure to steering arm is released. If the steering arm snaps up
the brake disc. Lowering the steering arm further abruptly, or does not return fully, the steering arm
increases the braking force. return spring requires adjustment. Return truck to
The brake may also be applied by raising the maintenance group for adjustment.
steering arm to the upright position.
2-8. LIFT/LOWER CONTROL.
5. To travel in reverse, lower the steering arm to a
comfortable position and slowly press the upper The LIFT/LOWER control, Figure 2-5, is used to lift the
portion of the speed control or rotate the grips forks and to regulate their lowering. The rate of rise is
upward. fixed, however, the descent of the forks is infinitely
variable. The farther the control lever is moved from
NOTE: Acceleration in reverse is the same as in the neutral position, the faster the forks will descend.
forward direction.
If the optional LIFT and LOWER pushbuttons on the
control handle or optional LIFT (UP) and LOWER
2-6. BELLY-BUTTON SWITCH GUARD.
(DOWN) remote control box are used, the lift carriage
The belly-button switch guard minimizes the possibility raises and descends at a fixed rate of speed.
of the driver being pinned by the steering arm while Proceed as follows to raise and lower the forks. If truck
driving the lift truck in reverse. If the guard presses is equipped with a key switch, turn it to the on position.
against the driver while the lift truck is being driven in
reverse, the guard actuates a switch which changes

PDI0404 2-5
 R5802

Figure 2-5 Lift/Lower Lever

WARNING: Check the space above the mast and the 3. Raise forks to desired height. Move truck into
load to be sure that there is sufficient position so forks are within pallet or skid, and the
room for raising the forks. Make sure the load is centered over the forks and as far back as
load is centered and does not exceed possible.
capacity. 4. Raise forks slightly to lift load from rack.
1. To raise the forks, pull LIFT control lever toward 5. Slowly reverse the truck to move load free from
UP position (toward operator), and hold it until the rack. When the load is clear, lower the load, leav-
forks reach the desired height; then return LIFT ing enough floor clearance to maneuver truck.
control lever to its neutral position. If truck is 6. Drive to area where load is to be placed.
equipped with pushbuttons, push in the LIFT but-
ton and hold until lift carriage reaches desired lift 7. Move truck to align load with its new position.
height. Raise forks to desired height.

2. To lower the forks, push LIFT control lever toward 8. Lower the load until it rests squarely in place and
DOWN position (away from operator), and hold it forks are free.
until the forks reach the desired height. Then 9. Slowly move the truck straight backward, making
return LIFT control lever to its neutral position. If sure the forks do not catch on the pallet. Lower
truck is equipped with the optional LOWER push- the forks when they are clear.
button, push in and hold the LOWER button until
lift carriage is at the desired height. 2-10. PARKING.
When finished with moving loads, drive truck to its
2-9. LOADING AND UNLOADING. maintenance or storage area. Disconnect batteries
1. Move truck to location where load is to be picked from TRUCK receptacle and connect to CHARGER
up. receptacle. Charge batteries as necessary. Refer to
2. Adjust forks to maximum practical width. battery care instructions, paragraph 3-3. or 3-4.

2-6 PDI0404
 SECTION 3
PLANNED MAINTENANCE

3-1. GENERAL. 3-3. WET CELL BATTERY CARE.

Planned maintenance consists of periodic visual and 3-3.1. General.
operational checks, parts inspection, lubrication, and
scheduled maintenance designed to prevent or dis- The life of the battery can be extended by giving it
cover malfunctions and defective parts. The operator proper care. Perform a daily check of the battery
performs the checks in SECTION 2, and refers any whether or not the equipment is in daily use. DO NOT
required servicing to a qualified maintenance techni- overcharge the battery or battery life will be shortened.
cian who performs the scheduled maintenance and DO NOT allow battery to become completely dis-
any required servicing. charged (specific gravity 1.150 or less). This will also
greatly shorten battery life.
3-2. MONTHLY AND QUARTERLY CHECKS. CAUTION: Observe and adhere to battery safety
Table 3-1 is a monthly and quarterly inspection and and maintenance supplement (Docu-
service chart based on normal usage of equipment ment 245) and battery warning decal
eight hours per day, five days per week. If the lift truck when servicing battery charger.
is used in excess of forty hours per week, the fre-
quency of inspection and service should be increased After charging, check the water level in each cell.
accordingly. These procedures must be performed by Water level must cover plates but not be higher than
a qualified service technician or your Big Joe service the base of the battery cell filler neck.
representative.

Table 3-1 Monthly and Quarterly Inspection and Service Chart

VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check condition of drive motor commutator, brushes and springs
Monthly Check condition of pump motor commutator, brushes and springs
Monthly Check mechanical brake for proper operation
Monthly Check load wheels for wear
Monthly Check drive wheel for wear
Monthly Inspect wiring for loose connections and damaged insulation
Monthly Inspect contactor tips for excessive pitting and wear
Monthly Check deadman brake switch for proper operation
Monthly Check lift chain tension, lubrication & operation (see paragraph 3-6.)
Quarterly Check lift cylinder wiper ring and packing for leakage
Quarterly Check for excessive jerking of steering arm when stopping or starting
Semi-annually Replace hydraulic filter assembly
Semi-annually Inspect for chain wear (See pargraph 8-3.)

PDI0404 3-1
3-3.2. Timer Charger Operation. Truck Serial Number 342392 To 376499, reinstall
and position battery retainer bar to prevent battery
The batteries must be pulled out of the compartments
movement in excess of 1/2".
in order to check the specific gravity.
Use the following procedure:
Truck Serial Number 342392 To 376499, remove
screw, washer and retainer bar by each battery. 1. Obtain a battery hydrometer.

CAUTION: These batteries are heavy. Use handles NOTE: These can be obtained from a local hardware
on battery when lifting. store or automotive shop.

Remove batteries from the right side of the truck. The 2. Use the hydrometer to check specific gravity of
battery connecting cables are sufficiently long to allow each cell.
batteries to be placed on the floor. It is not necessary
to disconnect the battery cables. NOTE: Battery specific gravity readings should agree
within + 0.025 from cell to cell. If variation is
When reinstalling the battery be sure battery cable greater, the battery may have to be repaired
connectors are securely attached to the battery termi- or replaced.
nals, and cables are routed and secured to the battery
as shown in Figure 3-1.

USED ON TRUCKS
SERIAL NUMBERS
342392 TO 376499

R5803

Figure 3-1 Reinstalling the Battery

3-2 PDI0404
CAUTION: Be sure that no cell plates are exposed
(not covered by fluid) before charging. Trucks Serial Numbers 333375 to 344163:
Add distilled water sufficient to just cover When charger light is off, charge cycle is com-
top of cell plates. plete.

CAUTION: Use distilled water. Impurities in tap 6. Disconnect AC power cord, wind up cord on cord
water will damage battery plates. winder.
7. Disconnect DC battery supply from the charger
3. When using a timer charger, charge battery in circuit and connect it to the truck.
accordance with Table 3-2. When using the
"smart" charger charge battery as described in 3-4. GEL CELL BATTERY CARE (OPTIONAL).
paragraph 3-3.3.
3-4.1. General.
NOTE: A fully charged battery has a specific gravity
of 1.260 to 1.275. These Gel Cell Batteries are maintenance-free. Any
attempt to open the battery will void the warranty.
3-3.3. Smart Charger Operation.
Ultra-deep discharging of brand new batteries
Big Joe "Smart" Chargers incorporate computer logic should be avoided for at least 15 cycles. To dramat-
circuits to provide full automatic recharging and shut ically extend battery life, ultra-deep discharge should
off operation for convenient overnight service. be avoided. THe shallower the average discharge, the
The operation of this charger is completely automatic. longer the battery life.

1. Turn key switch off, if equipped. 3-4.2. Charging Batteries

2. Check battery fluid levels (SEE Supplement Bat- Charging requirements will vary depending on depth
tery Safety and Maintenance Document 245). of discharge and temperature. Follow safety rules
3. Plug AC cord into proper AC power source. Dis- when placing a battery on charge.
connect DC battery supply from the truck and Proceed as follows:
connect it to the charger circuit. After a short
delay the charger will start. 1. Park truck at charging station with platform low-
ered and key switch off.
Table 3-2 Charger TIme for Battery Charging
2. Check the condition of the AC cord, the battery
SPECIFIC CHARGE TIME connector and battery cables. If there are any cuts
GRAVITY 15 AMP CHARGER in the cable, any exposed wires, loose plugs or
150 AH BATTERIES connectors, DO NOT attempt to charge the batter-
1.250 2 ies. Contact appropriate personnel for repairs to
1.240 4 be made.
1.220 5 3. Disconnect the batteries from the truck and con-
1.200 8 nect batteries to the charger. Make sure connec-
1.180 10 tors are mated properly.
1.160 12 4. Connect the AC cord to the truck and then plug
1.140 14 into the 120 VAC power supply.
5. The battery charger is fully automatic and will
CAUTION: Do not use truck while charger is cycle automatically (depending on amount of
plugged in. charge needed). Charge status can be observed
as follows (Refer to Figure 3-2):
4. Charger output will decrease as batteries
recharge. a. The top three LED’s indicate charger status.
At start of charge the RED (Charge) LED will
5. Trucks Serial Numbers 344163 To 376499:
be ON indicating the batteries are connected
When ammeter reads near 0, charge cycle is
and charging. After the batteries charge to
complete. The ammeter needle may cycle
approximately 80% the Yellow LED comes
momentarily to a higher reading and fall back to
ON. After a time (1 hour minimum) the Green
near 0. The red charger light stays on until the
LED comes ON indicating battery ready.
charger is unplugged from AC outlet.

PDI0404 3-3
NOTE: The battery charger includes an override
timer which terminates the charge if the cycle
does not complete after 18 hours of charging.
This time-out condition is indicated by the
green LED flashing off and on, and it indi-
cates a fault condition which should be inves-
tigated. This will occur if the charger cannot
raise the battery voltage to the preset voltage
limit. Possible causes indicate a battery fault,
a charger fault, low AC power supply voltage,
or excessive discharge. The override timer
can be reset by switching the AC power to the
charger off.
Figure 3-2 Charge Indicator
b. The lower four red LED’s indicate current
flow. Normally at start of charge, if the batter- 3-4.3. Removing Batteries from Charger
ies are discharged, all four red LEDs will be
on indicating maximum 25A charge current. 1. The Green “READY“ LED stays on until the
As the batteries charge the current drops and charger is unplugged from AC outlet.
the LEDs go OFF as the current drops to 2. Disconnect AC plug from the power supply and
20A, 15A, 10A and 5A respectively. then remove it from the truck.
3. Disconnect the batteries from the charger and
connect the batteries to the truck. Make sure con-
nectors are mated properly.

3-4 PDI0404
3-5. LUBRICATION. Table 3-3 Recommended Lubricants
(See Table 3-4 for Application)
Refer to Table 3-3 for the recommended types of
grease and oil. Table 3-4 in conjunction with Figure 3-3 No. 1 Transmission oil—EP SAE 80W-90
identifies the items requiring lubrication. Transmission oil—EP SAE 10W30 (Note)

3-6. LIFT CHAIN MAINTENANCE No. 2 Grease—Lithium base, general purpose.

Fully raise and lower lift carriage while observing
chains they move over all chain sheaves, Ensure chain No. 3 Hydraulic oil-Heavy duty with a viscosity of
is aligned and tracking properly and all links are pivot- 150 SUS (in temperatures below 32°F
ing freely. With carriage fully lowered, spray or brush use 100 SUS) foam suppressing agent
on a film of SAE 30 or 40 engine oil. and rust and oxidation inhibitors.

Big Joe Part No.900855 (1 gallon)

900893 (1 quart)

No. 4 SAE 30 or 40 Engine Oil

NOTE: USED ON COLD CONDITIONED TRUCKS

PDI0404 3-5
 R5815

Figure 3-3 Lubrication Diagram

Table 3-4 Lubrication Chart
FIG 3-2 LOCATION METHOD OF TYPE APPLICATION
INDEX APPLICATION (Table OF
NO. 3-3) LUBRICANT
1 Hydraulic System — No. 3 With lift carriage fully lowered, fill
Capacity-6 quarts reservoir with hydraulic oil to
"FULL" mark on dip stick.
2 Lift carriage rollers Gun No. 2 Pressure lubricate.
3 Load Wheels Gun No. 2 Pressure lubricate.
4 Mast rollers Gun No. 2 Use point adapter for Female
grease fitting.
5 Outer and inner mast Brush No. 2 Full length of channel where rollers
operate
6 Upper mast roller and Can No. 4 1 or 2 drops between bearings and
bracket (Serial Num- bracket.
ber 333375 to 338206)
7 Ram head sheaves Gun No. 2 Pressure lubricate.
8 Fork shaft Brush No. 2 Light coating.
9 Transmission Can No. 1 Fill to Hex plug (Fill level plug)
Capacity 4 1/2 pints level. Remove vent and fill
through vent hole.
10 Steering arm elbow Can No. 4 1 or 2 drops each time serviced.
11 Lift Chains Brush or Spray No. 4 See Paragraph 3-6.

3-6 PDI0404
 SECTION 4
TROUBLESHOOTING

4-1. GENERAL
1. SEE SUPPLEMENT 207 FOR TRANSISTOR Table 4-1 serves as a guide to determine possible
CONTROL HEAD USED ON TRUCKS SERIAL causes of trouble. The table is divided into five main
NUMBER 333375 TO 334630 categories: Truck Dead: Trouble With Travel: Trouble
2. SEE SUPPLEMENT 220 FOR TRANSISTOR With Braking: Trouble With Lifting Or Lowering, and
CONTROL HEAD USED ON TRUCKS SERIAL Miscellaneous malfunctions. Refer to electrical wiring
NUMBER 334631 TO 376499 diagram (Figure 4-6 or Figure 4-7) as a supplement to
the troubleshooting chart or when tracing an electri-
3. SEE SUPPLEMENT 187 FOR TRANSISTOR cal circuit.
CONTROLLER USED ON TRUCKS SERIAL
NUMBER 333375 TO 338589
4. SEE SUPPLEMENT 233 FOR TRANSISTOR
CONTROLLER USED ON TRUCKS SERIAL
NUMBER 338590 TO 372811
5. SEE SUPPLEMENT 349 FOR TRANSISTOR
CONTROLLER USED ON TRUCKS SERIAL
NUMBER 372812 TO 376499

Table 4-1 Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TRUCK DEAD
Truck will not run nor will lift sys- a. 120 Amp fuse blown. Check fuse and replace if defec-
tem operate. tive.
b. Battery dead or disconnected. Check battery quick-disconnect
plug and check battery voltage.
c. Keyswitch defective. Bypass keyswitch to determine if it
is malfunctioning.
d. 15 amp control circuit fuse Check fuse and replace if defec-
blown. tive.
e. Defective wiring. Check for open circuit. Repair as
required.
TROUBLE WITH TRAVEL Check all wiring. A loose connec- Tighten all loose connections
tion may be the cause of mal- before further troubleshooting.
function.
Truck does not run forward or a. 15-Amp control circuit fuse Check fuse and replace if defec-
reverse. Everything else is nor- blown. tive.
mal. b. Defective dead-man brake Check and replace brake switch if
switch. defective.
c. Forward or Reverse switch in Check and replace switch if defec-
control head broken. tive.
d. Main wire harness cut. Replace.
e. Belly button switch out of adjust- Adjust or replace.
ment or defective.

PDI0404 4-1
 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Truck runs forward, but not in Defective speed control switch in Check for positive dc voltage at
reverse. control head or defective contac- number 1 wire on reverse con-
tor. tactor. If not present when steer-
ing arm is in operating position
and speed control is in reverse,
speed control switch is defective.
If voltage is present, contactor is
defective.
Truck runs in reverse, but not in Defective speed control switch or Check for positive dc voltage at
forward. defective contactor. number 2-wire on forward con-
tactor. If not present when steer-
ing arm is in operating position
and speed control is in forward
speed, control switch is defec-
tive. If voltage is present, contac-
tor is defective.
Truck runs forward and in reverse a. Defective second and/or third Check coils for continuity. Replace
at slow speed; will not run at speed solenoids or contactors. as required.
higher speeds. b. Limit switch on mast defective Adjust or replace.
or out of adjustment.
c. Defective time delay. Replace.
Truck runs forward and in reverse Defective or open speed control Check for clean, tight connections.
at second or third speed only. resistor. Check resistor for continuity and
Truck does not move when con- replace as required.
trol is in first speed position.
Everything else is normal.
TROUBLE WITH BRAKING
Mechanical brake grabs when Brake linkage over adjusted. Ajust brake.
steering arm is in operating posi-
tion.
TROUBLE WITH LIFTING OR Check hydraulic oil level. Before
LOWERING further troubleshooting, fill
hydraulic reservoir so that oil is
to "FULL" mark on dip stick.
Tighten all electrical connec-
tions.
Oil sprays or flows from the top of Defective packing in lift cylinder or Overhaul lift cylinder and install
the lift cylinder. too much oil in reservoir. new packing, seal, and wiper
ring.
Oil foaming from vent cap on Leak in suction line between the Check oil filter. Replace if neces-
hydraulic reservoir. pump and the reservoir or oil too sary. Tighten fittings. Inspect line
high. and replace if necessary.

4-2 PDI0404
 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Oil splashes out of vent when low- Oil level too high. Drain, then refill reservoir to
ering forks. "FULL" mark on dip stick.
Squealing sounds when lifting a. Oil level too low. Add oil to reservoir.
forks. b. Dry channels in mast. Apply grease.
c. Defective mast or carriage bear- Replace bearing.
ing.
Forks do not lift to top. Pump a. Oil level too low. Add oil to reservoir.
motor runs. b. Load larger than capacity. Refer to nameplate on side of
mast for maximum load capacity.
c. Batteries are dead. Recharge.
Oil leaks out of lift control valve Defective O-ring in lift control valve Replace O-ring on release cam
release cam. body. shaft.
Lift control does not return to neu- a. Broken return spring. Replace return spring.
tral. b. Foreign particles. Clean system and valve.
c. Misalignment of valve clamp. Adjust as required.
Weak, slow or uneven action of a. Defective pump. Check pressure.
hydraulic system. b. Defective lift cylinder. Clean system and valve.
c. Load larger than capacity. Refer to name plate on side of
mast for maximum load capacity.
d. Dirt or foreign particles lodged Disassemble, clean and reassem-
between check ball and seat on ble valve.
lift control valve.
e. Defective lift control valve. Adjust, repair or replace.
f. Valve body scored inside. Replace valve.
g. Battery specific gravity low. Charge battery.
Forks do not lift, motor does not a. Battery is dead or discon- Check and recharge if required.
run. nected.
b. Defective wiring. Check and repair as required.
c. Defect in electrical system for Check pump motor switch on lift
operating pump motor. control valve, as well as the sole-
noid relays. Repair or replace.
Forks do not lift, motor runs. Defective in hydraulic system. 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.
Forks lift, but will not go down. Control valve in open position or Check the lowering control valve
defect in hydraulic system. as well as the flow control valve,
and look for obstruction in the
hydraulic line. Repair or adjust
as required.

PDI0404 4-3
 Table 4-1 Troubleshooting Chart - Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Load will not hold. a. Oil bypassing internally Disassemble, clean, and reassem-
between check ball and control ble. Replace worn parts as
valve body. required.
b. Worn lift cylinder packing. Replace cylinder packing.
Forks creep downward under load Leak in hydraulic system, packing, Examine the lift control valve and
when in a raised position. or valve. internal check valve for obstruc-
tions preventing ball from closing
completely to block oil. Look for
leaking fittings in the hydraulic
line. Check pump and suction
line for leakage back into the res-
ervoir. Repair or replace as
required.
MISCELLANEOUS
Steering arm does not return to a. Return spring improperly Readjust spring tension.
the upright position. adjusted.
b. Binding brake linkage or electri- Check and free the binding item.
cal cable.
c. Broken spring Replace.
Truck moves forward when arm is a. Belly-button switch defective. Check for short, and repair or
pulled down. replace as necessary.
b. Short in control head. Check wiring and repair as
required.
c. Short in wiring harness through Replace.
pivot tube.
Steering arm jerks excessively a. Worn steering arm pivot bush- Replace bushings.
when starting or stopping the ings.
truck. b. Drive wheel tire worn. Replace drive wheel.
Drive motor is jerky. Motor commulator worn. Replace motor.

4-4 PDI0404
4-2. SMART CHARGER 004978 TROUBLESHOOT- mum output voltage. Incorrect setting of
ING (Trucks Serial Number 344163 To 376499) this potentiometer can cause damage to
the charger or batteries.
The logic flow troubleshooting diagram provides a sim-
plified means of isolating the probable cause for a WARNING: A jumper is used on the printed circuit
problem by performing steps to obtain a "Yes" or "No" logic board for part of the test. This
answer. Three types of blocks are used. Rectangular jumper must be installed with the
boxes with a regular border provide procedural infor- charger disconnected from the AC power
mation. Rectangular boxes with bold borders identify input.
a probable fault. Diamond shaped boxes ask a ques-
tion to obtain a yes or no answer. By following the yes Refer to Figure 4-1 for a complete schematic of the
and no lines the problem is identified. charger. Figure 4-2 provides information of connecting
the jumper when necessary. Figure 4-3 is a logic flow
CAUTION: Do not ever change the setting on the troubleshooting guide.
potentiometer on the printed circuit
board. This is factory set to limit maxi-

120 V AC MALE OUTLET

PLUG FLANGED AMMETER
GR

CHARGER
CONNECTOR
15A
FUSE

CIRCUIT
BREAKER

INDICATOR LOGIC BRD

SINK L HEAT SINK

LOGIC
BOARD
TRANSF

R5962
(120 VAC) AUTOMATIC CHARGER
Figure 4-1 Battery Charger Schematic

JUMPER

R5963 TO CIRCUIT
BREAKER
Figure 4-2 Logic Board Jumper Position

PDI0404 4-5
 1.Disconnect charger
from battery
2.Connect charger to
AC input power
source

Is Is 24
VDC to 28 Is 24
approximately VDC to 28
48 VAC VDC present
Is indicator YES YES Connect battery between input to YES VDC present from YES
present across battery positive (+) side
light turned on? green wires from to charger circuit breaker (two
red wires) and of circuit breaker
transformer to to heatsink?
logic heat
board? sink?

NO NO NO
NO
Replace transformer Check battery charger
Disconnect charger
output cable and
from AC power source
Is 120 VAC connector for
present across YES Check indicator light continuity, replace or
transformer connection, replace if repair.
faulty Install jumper on circuit Check for faulty
input?
board as shown in circuit breaker,
Figure 3 replace if necessary.

NO
Reconnect charger to
Check input AC fuse AC power source
and check that power
is present from power
source

Is 24
VDC to 28
VDC now present YES Logic board faulty,
at input to circuit replace logic board
breaker?

NO
Faulty diodes, replace
logic board

R5964A

Figure 4-3 Logic Flow Diagram (Sheet 1)

4-6 PDI0404
 YES Disconnect AC input
power to the charger

Using an ohmmeter, Measure resistance

check resistance from Is resistance YES between side of YES Ammeter faulty
negative side of ammeter connected Is resistance
greater than
connector to chassis to charger and near 0 ohms? replace ammeter
100 Ohms
ground. chassis ground.

NO NO
Check connection
Charger ok
between ammeter
and logic board

R5964B

Figure 4-3 Logic Flow Diagram (Sheet 2)

PDI0404 4-7
4-3. OPTIONAL GEL CELL BATTERY CHARGER a. Verify 25 VAC from blue wire to each white
004987 TROUBLESHOOTING wire.
(Trucks Serial Number 344163 To 376499)
b. Verify 50 VAC from the white wire to white
Refer to Figure 4-5 for part identification. Be sure the wire.
batteries are connected to the charger and the AC
c. If these voltages were not indicated, replace
cord is connected to 120 VAC power supply.
the transformer.
4-3.1. Dip Switch Setting (Figure 4-4)
4-3.5. Circuit Board Testing
The DIP switches on the Printed Circuit Board (PCB) The circuit board has a built in diagnostic test at
must be set for Gel Cell Batteries. Check that switch 1 power-up.
is ON and switch 2 is OFF.
1. Switch the AC supply OFF and then ON, watching
the 3 upper LEDs on the PCB. The 3 LEDs should
light briefly in sequence Green-Yellow-Red when
power is applied. This indicates the transformer is
OK and that power is getting to the PCB.
R6120
Figure 4-4. Dip Switch Settings 2. If the battery DC is connected to the charger cor-
rectly, the Red LED should come ON immediately
4-3.2. Thermistor after this test sequence.
There is a temperature sensing thermistor plugged 3. If the Green-Yellow-Red LED test sequence does
into a 2-pin socket marked THERM on the PCB. Check not show at power-up, or if it cycles constantly
that this is firmly connected or the battery voltage con- Green-Yellow-Red, the PCB assembly should be
trol will not work properly. replaced.
4-3.3. Circuit Breaker Testing 4. If the Red or Yellow charging LED does not stay
ON after the test sequence, check that the batter-
Using a multimeter set to measure 120 VAC, check ies are connected to the charger.
each side of the circuit breaker to ground. If 120 VAC
was not indicated on both sides, replace the circuit 5. Using a multimeter set to measure at least 30
breaker. VDC, verify DC Voltage from Black to Red wire is
as follows:
4-3.4. Power Transformer Testing a. If the Red charging LED is on and the Yellow
The two 0.250” tabs are the primary side of the trans- charging LED is off, voltage from black to red
former and five #10 screw lugs are the secondary side. wire should be at least 24 VDC.
Test the Transformer as follows:
b. If the Red and Yellow charging LEDs are on,
1. Using a multimeter set to measure at least 120 voltage should be 29 ±1 VDC.
VAC, verify that AC Power supply 120V 60Hz
input is present at the transformer primary termi- c. If there is no Voltage, check the wiring and
nals. If 120 VAC was not indicated, check the cir- connections from the charger to the battery
cuit breaker and wiring. terminals. Battery Voltage must be correct
polarity and more than 1 Volt to commence
2. Using a multimeter set to measure at least 50 charging.
VAC, verify the transformer secondary terminals
as follows:

4-8 PDI0404
 R6132

Figure 4-5. Battery Charger Wiring Diagram

PDI0404 4-9
 USED ON TRUCKS 1. SEE SUPPLEMENT 187 FOR TRANSISTOR TRUCKS
SERIAL NUMBERS SERIAL NUMBER 333375 TO 338589
333375 TO 364407 2. SEE SUPPLEMENT 233 FOR TRANSISTOR TRUCKS
SERIAL NUMBER 338590 TO 364407

R5816A

Figure 4-6 Wiring Diagram (Sheet 1)

4-10 PDI0404
 1. SEE SUPPLEMENT 187 FOR TRANSISTOR TRUCKS USED ON TRUCKS
SERIAL NUMBER 333375 TO 338589 SERIAL NUMBERS
333375 TO 364407
2. SEE SUPPLEMENT 233 FOR TRANSISTOR TRUCKS
SERIAL NUMBER 338590 TO 364407

R5816B

Figure 4-6 Wiring Diagram (Sheet 2)

PDI0404 4-11
 USED ON TRUCKS 1. SEE SUPPLEMENT 233 FOR TRANSISTOR TRUCKS
SERIAL NUMBERS SERIAL NUMBER 364408 TO 372811
364408 TO 376499 2. SEE SUPPLEMENT 349 FOR TRANSISTOR TRUCKS
SERIAL NUMBER 372812 TO 376499

R6084A

Figure 4-7 Wiring Diagram (Sheet 1)

4-12 PDI0404
 1. SEE SUPPLEMENT 233 FOR TRANSISTOR TRUCKS USED ON TRUCKS
SERIAL NUMBER 364408 TO 372811 SERIAL NUMBERS
364408 TO 376499
2. SEE SUPPLEMENT 349 FOR TRANSISTOR TRUCKS
SERIAL NUMBER 372812 TO 376499

R6084B

Figure 4-7 Wiring Diagram (Sheet 2)

PDI0404 4-13
 NOTES

4-14 PDI0404
 SECTION 5
STEERING ARM AND CONTROL HEADS SERVICING

5-2. COLD CONDITIONING.

1. SEE SUPPLEMENT 207 FOR TRANSISTOR The cold conditioning version of the truck differs from
CONTROL HEAD USED ON TRUCKS SERIAL the standard model where necessary to improve per-
NUMBER 333375 TO 334630 formance in cold temperatures. Heating resistors are
2. SEE SUPPLEMENT 220 FOR TRANSISTOR provided for the control head switches, and cold resis-
CONTROL HEAD USED ON TRUCKS SERIAL tant versions of other switches and the hydraulic hoses
NUMBER 33461 TO 376499 are used. Special cold temperature lubricants are also
necessary for this application.
Figure 5-2 is an electrical schematic diagram of the
5-1. GENERAL.
cold conditioning circuit. Location of electrical parts in
The following procedures cover adjustments, replace- the control head and resistor wiring of cold condition-
ment, and repair of the steering arm, control head, and ing equipment is illustrated in Figure 5-3.
related assemblies and components. The procedures
are independent of each other unless specifically ref- CAUTION: Cold conditioning heating resistors con-
erenced. sume power when energized, whether
truck is used or not. To avoid power
Speed controls are located on the inner hand grips, waste, disconnect battery of cold condi-
with optional twist grip speed control provided. The tioned truck when lengthy storage peri-
control head provides three speed progressive speed ods at temperatures low enough to
control selection. energize cold conditioning equipment
are planned.

R960 R6178

Figure 5-1 Belly-Button Switch Adjustment Figure 5-2 Schematic of Cold Conditioning Circuit

PDI0404 5-1
 CAUTION: While removing the belly-button casting,
two springs (needed for reassembly) will
fall free.

2. Being careful to catch and retain the belly-button

springs (25, Figure 5-4) that may fall from the con-
trol head (41) as the belly-button casting (42) is
removed, drive out the roll pins (11) that secure
the belly-button casting.

CAUTION: A misaligned switch may actuate (click)

early or late in travel, or fail to operate.

WARNING: Test switch in an open area to avoid

being accidentally pinned.

3. Bend actuator lever of belly-button switch (Figure

5-1) to adjust gap so that switch clicks half way
through travel of casting.
4. Reinstall casting, making certain all parts are
back in place.
R3964 5. Check operation of the belly-button switch by
pressing the belly-button casting while listening
Figure 5-3 Location of Resistors and for the “click” that indicates that the switch has
Thermal Cutout Switch actuated.

5-3. BELLY-BUTTON SWITCH ADJUSTMENT. NOTE: The click should be heard when the belly-but-
ton casting has moved about 50 per cent of
NOTE: Adjust the actuator gap of the belly-button its normal travel distance. If the click is heard
switch according to the following procedure. at the beginning of travel, the switch may
Refer to Figure 5-1 and Figure 5-4. actuate at inappropriate times. If the click is
heard near the end of travel, the switch could
NOTE: All electrical connections should be tagged
be unreliable and may not actuate in some
with identifying labels before disconnecting.
instances.
1. Disconnect battery.

5-2 PDI0404
 1. SEE SUPPLEMENT 207 FOR
TRANSISTOR CONTROL HEAD
USED ON TRUCKS SERIAL
NUMBER 333375 TO 334630
2. SEE SUPPLEMENT 220 FOR
TRANSISTOR CONTROL HEAD
USED ON TRUCKS SERIAL
NUMBER 33461 TO 376499

R3837

Figure 5-4 Control Head Assembly

PDI0404 5-3
6. Repeat steps 2 through 5 until pressing the belly- 6. Replace switch plate (18, Figure 5-5) and secure
button casting actuates the switch properly. with four screws (15 and 16, Figure 5-4) on top
7. Reconnect battery and electrical connections. and bottom of control handle (41, Figure 5-4).
7. Replace top cover (15, 16, or 17, Figure 5-5) of
WARNING: Testing of belly-button switch in opera- control head, and secure with four screws (14).
tion should be limited to areas clear of
obstacles against which an operator 8. Reconnect battery.
could be pinned. Use first speed,
reverse. 5-5. SPEED CONTROL SWITCH RETURN SPRING
REPLACEMENT.
5-4. CONTROL HEAD SWITCH REPLACEMENT. NOTE: Refer to Figure 5-4, Figure 5-5 and Figure 5-6
NOTE: Refer to paragraph 5-5. for speed control for the following procedure.
switch replacement. 1. Disconnect battery.
NOTE: For access to belly-button switch, see para- 2. Remove four screws (24, Figure 5-6) securing
graph 5-3. For access to other switches on control head to steering arm.
the control head, the top cover (15, 16, or 17, 3. Disconnect connector (23).
Figure 5-5) and/or switch plate (18) must be
removed. 4. Remove four screws (14, Figure 5-5) securing top
cover (15) to control head.
NOTE: All electrical connections should be tagged 5. Disconnect speed control switches (4, Figure 5-
with identifying labels before disconnecting. 4).
1. Disconnect battery. 6. Remove four screws (17) securing handle guard
2. If necessary to gain access to defective belly-but- (36) to control head.
ton switch, remove belly-button casting (42, Fig- 7. Remove two socket head screws (18) and caps
ure 5-4) by performing step 2. in paragraph 5-3. (29) from handle guard (36).
3. Remove top cover (15, 16, or 17, Figure 5-5) of 8. Remove handle guard with two brackets (33 and
control head by removing four screws (14). 39) and speed control switches (4) attached.
4. Remove switch plate (18, Figure 5-5) by removing 9. Remove roll pin (10) from right hand handle grip
four screws (15 and 16, Figure 5-4) on top and (31).
bottom of control handle (41, Figure 5-4). 10. Remove right hand handle grip from shaft (28).
5. Replace belly-button switch (3, Figure 5-4), speed 11. Remove set screw (22) from right hand control
control switch (4, Figure 5-4), horn switch (4, Fig- lever (40).
ure 5-5), or lift and lower switches (3, Figure 5-5).
12. Remove right hand control lever from tube (34).
NOTE: If the belly-button switch is replaced, adjust it
in accordance with paragraph 5-3. before
using truck.

5-4 PDI0404
 1. SEE SUPPLEMENT 207 FOR TRANSISTOR CONTROL HEAD USED ON TRUCKS SERIAL
NUMBER 333375 TO 334630
2. SEE SUPPLEMENT 220 FOR TRANSISTOR CONTROL HEAD USED ON TRUCKS SERIAL
NUMBER 33461 TO 376499

R3838

Figure 5-5 Push Button Switches

PDI0404 5-5
13. Observing through top cover opening, slide shaft tube (2) will rotate counterclockwise when screw
(28) with tube (34) out left hand side of control is loosened.
head just enough to clear return spring (24). 4. With a pair of vise grip pliers, grip the flat surfaces
14. Disengage return spring from spirol pin (12) and of the spring tube assembly (2) and rotate clock-
remove return spring. wise 180 degrees.
15. Place new return spring in position, engage with 5. Hold spring tube assembly in rotated position and
spirol pin, and slide shaft (28) with tube (34) back tighten screw (13) to secure.
through return spring and out right hand side of 6. Check the spring action by lowering the steering
control head. arm and returning it to the upright position two or
16. Install right hand control lever (40) onto tube (34), three times.
and secure with set screw (22). 7. If necessary, repeat steps 2. through 6., increas-
17. Install right hand handle grip (31) onto shaft (28), ing or decreasing amount of rotation of the spring
align roll pin hole in handle grip with roll pin hole in tube assembly until steering arm returns gently to
shaft, and install roll pin. full upright position.
18. Install handle guard (36), with two brackets (33 8. Reconnect battery.
and 39) and switches (4) attached, and secure
with two caps (29) and screws (18). 5-7. STEERING ARM RETURN SPRING
19. Install four screws (17) through handle guard and REPLACEMENT.
into control head. NOTE: Refer to Figure 5-6 for the following proce-
20. Reconnect speed control switches (4). dure.
21. Install top cover (15, Figure 5-5) with four screws NOTE: The steering arm return spring is replaced
(14). while the steering arm is in the upright posi-
22. Reconnect connector (23, Figure 5-6). tion.
23. Install control head onto steering arm with four 1. Disconnect battery.
socket head screws (24, Figure 5-6).
24. Reconnect battery. NOTE: The steering arm has a tendency to fall down-
ward when the tension on the return spring is
5-6. STEERING ARM RETURN SPRING released.
ADJUSTMENT. 2. Hold steering arm (12, Figure 5-6) in upright posi-
The tension on the steering arm return spring should tion and make sure the arm cannot fall.
allow the steering arm to return gently to the upright 3. With a piece of chalk or crayon, draw a straight
position. Excessive tension on the steering arm return line from center of spring tube assembly (2) into
spring will cause the steering arm to snap up and may pivot cap (3), marking radial position of tube, to
cause damage to the electrical cable, brake linkage, or facilitate reinstallation.
the spring itself. If the steering arm does not return
4. Insert a 5/16 allen wrench through hole in bottom
fully, check for binding in the brake linkage or wiring
of steering arm and loosen screw (13).
harness before making any adjustments. If they do not
bind, refer to Figure 5-6 and proceed as follows to CAUTION: Unless properly supported, steering arm
adjust the steering arm return spring tension. will drop out of pivot cap when spring
tube is removed.
NOTE: Refer to Figure 5-6 for the following proce-
dure. 5. Put a block under steering arm at pivot cap.
1. Disconnect the battery. 6. With a pair of vise-grip pliers, grip the flat surfaces
of spring tube assembly (2), and slowly pull it free
2. Hold the steering arm (12, Figure 5-6) in the
from the steering arm, pivot cap and tube clamp
upright position and make sure the arm cannot
(10).
fall.
3. Insert a 5/16 allen wrench through hole in bottom NOTE: Steering arm return spring (1) will remain
of steering arm and loosen screw (13). The spring inside the spring tube assembly (2).

5-6 PDI0404
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 345826
345828 TO 345865
345871 TO 345389

HANDLE RETURN SPRING KIT

PART NUMBER 901325
CONTAINS:
ITEM QTY
1 1
2 1
R5806 10 10

Figure 5-6 Steering Arm and Electrical Cable

7. Remove steering arm return spring (1) from 10. Slide spring tube assembly into pivot cap (3) and
spring tube assembly (2). If spring is severely steering arm (12) through tube clamp (10) and
jammed and will not come loose, punch and drive through loop of electrical cable.
the 1/4-inch diameter roll pin (29) into the tube. 11. Align radial position of spring tube assembly in
Save pin for reuse. Remove the spring. Tap roll accordance with line drawn in step 3. Slowly
pin back into place. rotate spring tube assembly a few degrees each
8. Lubricate the ends and outer surface of the new way until the steering arm return spring snaps into
steering arm return spring (1) with a lithium base place over spring pins (6 and 7) then tighten
general purpose grease. screw (13).
9. Insert spring into spring tube assembly and press 12. Apply engine lubricating oil (No. 2) to the steering
in, making sure that one spring loop eye fits over arm elbow.
the 3/8-inch roll pin at the closed end of the spring 13. Remove block from under steering arm.
tube assembly.
14. Adjust tension on steering arm return spring as
explained in paragraph 5-6.
15. Reconnect battery.

PDI0404 5-7
5-8. PIVOT TUBE FLANGED BUSHING 5. Disconnect the wire to the horn.
REPLACEMENT. 6. Disconnect the four cables connected to the drive
NOTE: Replacement of the flanged bushings motor.
requires the removal of the steering arm and 7. Disconnect brake rod from brake lever by remov-
pivot cap, transmission, and pivot tube ing cotter pin.
assembly. 8. Trucks Serial Number 333375 to 345826,
NOTE: All electrical connections and cabling should 345828 to 345865, 345871 to 345389, remove
be tagged with identifying labels before dis- two socket head screws (26, Figure 5-6) securing
connecting. pivot cap cover (25).
9. Remove pivot cap cover (25).
NOTE: A chain hoist is required for this procedure.
10. Remove pivot cap with electrical control cable,
1. Disconnect battery. brake rod, steering arm and control head from
2. Block load wheels securely. pivot tube assembly.
3. Disconnect connector (9, 5-9.). 11. Remove cotter pin (5, Figure 5-7) from pin (6),
then remove pin (6) from upper spacer (7) on
4. Disconnect the wires to the dead man switch. pivot tube.

USED ON TRUCKS
SERIAL NUMBERS
333375 TO 339404

R5807

Figure 5-7 Pivot Tube Assembly

5-8 PDI0404
12. Remove lower spacer mounting hardware as fol- 17. Alternately raise the truck frame and then the
lows: pivot tube several more inches, until enough
clearance is provided to lift out the transmission
a. Truck Serial Number 339404 To 376499,
assembly with the drive wheel and motor and
remove set screw (14) from lower spacer (13)
brake assembly.
on pivot tube.
b. Truck Serial Number 333375 to 339404, WARNING: The following step requires two people
remove socket head screw (9) and lock- as heavy lifting is involved.
washer (8) from lower spacer (12) on pivot
18. Lift out the transmission assembly with the drive
tube.
wheel and motor and brake assembly.
13. Using jacks or another lift truck, raise truck frame
19. Slowly lower the pivot tube through the upper and
around drive wheel enough to provide clearance
lower pivot tube housing until the top of the pivot
for access to four socket head screws securing
tube is half way between the upper and lower
pivot tube to transmission.
pivot tube housing.
14. Remove the four socket head screws (11) secur-
20. Block the pivot tube in position.
ing the pivot tube (10) to the transmission.
21. Remove the hoist chain and the two pivot cap
15. Position a chain hoist above the pivot tube.
cover screws or pivot tube tool as applicable.
16. Connect chain to pivot tube as follows: 22. Remove the upper bushing (1, Figure 5-7), spacer
a. Trucks Serial Number 333375 to 345826, (3), bearing (4), and upper spacer (7).
345828 to 345865, 345871 to 345389, using 23. Remove lower spacer (12 or 13) and lower bush-
the two pivot cap cover screws (26, Figure 5- ing (1).
6) as a means of attachment for the chain,
install the two screws onto the pivot tube with 24. Inspect the bearing (4) for wear. If worn, replace
the chain attached. with new bearing.
25. Discard the two old bushings (1).
b. Trucks Serial Number 345827, 345866 to
345870, 345390 To 376499, use tool kit part NOTE: When installing the new bushings with spac-
number 907151. Position spacer, Figure 5-8, ers and bearings, refer to Figure 5-7 to be
inside the pivot tube. Insert the pin through sure they are positioned on pivot tube in the
the support tube and secure with the cotter proper order.
pin. Attach chain hoist to the spacer.
26. Place new bushing (1), spacer (12 or 13), spacer
(7), bearing (4), spacer (3), and bushing (1)
TOOL KIT around pivot tube (10). Do not install lower bush-
907151 CONTAINS: ing (1) onto lower pivot tube housing at this point.
1 COTTER PIN 27. Connect hoist chain to pivot tube as described in
1 PIN Step 16.
1 SPACER
28. Slowly raise the pivot tube, being careful to check
for alignment with the upper pivot tube housing,
until enough clearance exists to install the trans-
mission assembly with drive wheel and motor and
brake assembly.
29. Remove the blocks from under the pivot tube.
30. Position the transmission assembly (with drive
wheel and motor and brake assembly) in place for
installation.
31. Alternately lower the pivot tube and truck frame
until the pivot tube mounting base contacts the
R5432 transmission while leaving access for the mount-
ing screws.
Figure 5-8 Pivot Tube Removal Tool

PDI0404 5-9
32. Align the mounting screw holes, and install the 5-9. ELECTRICAL CONTROL CABLE REPLACE-
pivot tube onto the transmission with the four MENT.
socket head screws (11).
NOTE: Refer to Figure 5-9 while performing the fol-
33. Lower the truck frame fully and remove the lifting lowing procedure.
device.
34. Position the upper and lower bushings (1) on the 1. Disconnect battery.
upper and lower pivot tube housing with the roll NOTE: When removing control head in the following
pin holes aligned with the bushing roll pin cutouts. step, be sure to hold it in place until cable is
35. Position the bearing (4) and upper spacer (7) disconnected.
beneath the upper bushing (1) with the spacer pin
hole aligned with the pivot tube pin hole. 2. Remove four screws (7, Figure 5-9) that secure
control head to steering arm.
36. Install the pin (6) through the spacer (7) and pivot
tube (10). 3. Disconnect connector (8), and set aside control
head.
37. Install the cotter pin (5) onto the pin (6).
4. Use Amp Extraction Tool part number 900750 to
38. Position the lower spacer (12 or 13) against the push out and disconnect wire pins from connector
lower bushing (1). (8).
39. Install lower spacer mounting hardware as fol- 5. Remove cable clamps (1, 2) and loosen loop of
lows: cable that surrounds the spring tube assembly
a. Truck Serial Number 339404 To 376499, (3).
install set screw (14) and torque to 15 ft-lbs. 6. Remove pivot cap cover (6).
b. Truck Serial Number 333375 to 339404, 7. Pull disconnected end of old cable through steer-
align screw hole of lower spacer (12) with ing arm and pivot cap, then up through pivot cap
hole in pivot tube. Install the washer (8) and cover opening.
socket head screw (9) through the spacer
8. Tape the disconnected end of the old cable to the
(12) and pivot tube (10).
connector (9) on the new cable.
40. Remove the hoist chain and the two pivot cap
9. Grease the new cable with a lithium-base grease
cover screws or pivot tube tool applicable.
or silicone spray.
CAUTION: Be sure to observe cable routing and NOTE: The dead-man switch is on the brake linkage.
positioning when reinstalling electrical The wires connected to the pin numbers 3
control cable to prevent cable damage. and 8 on the connector (9) are wires that go
41. Reinstall pivot cap and steering arm onto pivot to the dead-man switch. The wire connected
tube, being careful not to damage electrical con- to pin 7 goes to the horn.
trol cable and brake rod. (See Figure 5-9).
10. Remove base access cover.
42. Reconnect the connector (9, Figure 5-9). 11. Disconnect connector (9) from contactor panel.
43. Reconnect the wires to the dead man switch.
12. Disconnect cable wire numbers 3 and 8 from the
44. Reconnect the wire to the horn. dead-man switch.
45. Reconnect the brake rod to the brake lever with 13. Disconnect cable wire number 7 from the horn.
cotter pin.
NOTE: When performing step 14., be sure to leave
46. Reinstall the pivot cap cover.
enough cable exposed through pivot cap
47. Reconnect the four motor cables. cover opening to loop around spring tube
48. Reconnect battery. assembly and reach through steering arm to
control head.
49. Remove the blocks from the load wheels.
50. Check truck for proper operation before returning 14. Draw new cable into pivot tube (10) by pulling old
to service. cable out through the base access opening.
15. Untape connector (8) end of old cable from con-
nector (9) end of new cable.

5-10 PDI0404
 R116

Figure 5-9 Electrical Control Cable Replacement

PDI0404 5-11
16. Connect the new cable connector (9) to the con- 22. Loop cable around spring tube assembly (3) as
nector on the contactor panel. illustrated and push connector (8) end of cable
17. Route and connect cable wire numbers 3 and 8 to through steering arm.
the dead man switch. 23. Secure cable with cable clamp (2).
18. Route and connect cable wire number 7 to the NOTE: Although a new connector (8) is supplied with
horn switch. the new cable, it is not attached. The new
19. Wipe off excess grease or silicone spray from connector (8) must be attached to the wire
exposed parts of the cable. connector pins of the new cable. Each wire is
20. Route connector (8) end of cable under spring numbered and must be connected to its cor-
tube assembly (3) and out the opening at the responding pin receptacle number in the con-
elbow. nector.

21. Eliminate cable slack in pivot tube (10); then 24. Plug the wire pins into their corresponding recep-
secure cable with cable clamp (1). tacles in the connector (8).

CAUTION: Improper cable loop adjustment while 25. Position the control head close enough to the
performing the following step will dam- steering arm to reach the connector (8).
age the cable. If too tight, the cable will 26. Reconnect the connector (8) to the corresponding
tear when the steering arm is in the up connector in the control head.
position. If too loose, the cable will 27. Secure the control head to the steering arm with
buckle or be pinched when the steering the four screws (7).
arm is in the down position.
28. Reconnect battery.

5-12 PDI0404
 SECTION 6
BRAKE SERVICING

6-1. ADJUSTMENT 1. Disconnect battery connections.

If the mechanical brake does not begin to hold when 2. Jack up the truck so the drive wheel is off the
the steering arm is raised or lowered into the lightly ground; then securely block the truck to prevent
shaded area in Figure 6-1, proceed as follows: slipping.
3. Remove service cover.
NOTE: Refer to Figure 6-1, Figure 6-2 and Figure 6-3
for the following procedure. 4. Secure steering arm assembly in a position that is
in either lightly shaded area shown in Figure 6-1.

R3629

Figure 6-1 Brake Engage/Disengage

PDI0404 6-1
5. Remove the cotter pin (4, Figure 6-2), then slide 16. Make sure that applying the brake activates the
the rod (2) into the brake lever (3) far enough to switch but does not fully depress the switch
pull the link pin (1) out of the lever (5). plunger. If necessary, repeat steps 14. and 15.
until the switch is properly positioned.
17. Lower the truck and install the service cover.
18. Reconnect battery connections.

6-2. REPLACEMENT OF DISC BRAKE PARTS

NOTE: Refer to Figure 6-3 for the following proce-

dure.
1. Disconnect battery connections.
2. Block the wheels to prevent the truck from rolling.
3. Secure the steering arm down from its park posi-
tion so that the brake is disengaged.
4. Remove service cover.
R3356
5. Remove the cotter pin (2, Figure 6-3) from the link
pin (17).
Figure 6-2 Adjustment
6. Slide the rod (16) with link pin (17) far enough into
6. Turn the link pin (1) to make the adjustment. the brake lever (15) to pull the link pin out of the
7. Slide the link pin (1) back into the lever (5), but do lever (29).
not insert the cotter pin (4) at this time. 7. Remove two screws (10) and lockwasher (9).
8. Spin the drive wheel by hand to check brake 8. Remove complete disc brake pad assembly (18)
adjustment. If there is no drag, go to step 9. If from plate, tapping lightly with a hammer if neces-
there is noticeable drag, go to step 11. sary.
9. Disconnect the link pin (1).
NOTE: Complete assembly can be replaced. Order
10. Repeat steps 6. through 8. until adjustment is cor- part number 052821.
rect providing noticeable drag.
9. If complete brake assembly is to be replaced pro-
11. Install the cotter pin (4).
ceed with step 18. If brake assembly is to be dis-
12. Secure the steering arm in drive position and spin assembled proceed with step 10.
the drive wheel to make sure there is no drag. If
there is any drag, carefully readjust only enough 10. Hold assembly (18) together, then remove the two
to eliminate drag in the drive position. nuts (19) and lock washers (31).

13. Remove the restrictions from the steering arm 11. Remove the bolts (20), springs (22), spacers (21),
and let the arm return to the upright position. and brake pad (23).
12. Remove the C-ring (24), washer (25), spring (26),
14. Check that the brake lever has activated the dead-
bracket (28), lever (29), and washer (30) from the
man brake switch and removed power from the
brake pad (27).
control circuits. If the switch is not activated, go to
step 15. If it is activated, go to step 17. 13. Discard the springs (22 and 26) and brake pads
15. Adjust the position of the dead-man switch by (23 and 27). Replace them with new parts.
loosening the screws attaching the switch to NOTE: For brake disc replacement refer to SECTION
bracket (8, Figure 6-3), then sliding the switch up 7, Transmission.
or down in the adjustment slots, and tightening
the screws. 14. Assemble the washer (30), lever (29), bracket
(28), spring (26), washer (25), and C-ring (24) to
the brake pad (27).
15. Assemble the brake pad (23), spacers (21), and
springs (22) to the two bolts (20).

6-2 PDI0404
16. Align the bolt holes in the bracket (28) and brake assembly lightly with hammer, if necessary to
pad (27), then slip the bolts (20) through the holes clear mounting plate opening.
in brake pad (27), mounting block (11) and 19. Slide the link pin (17) into the lever (29) and
bracket (28) and hold the assembled parts secure the link pin with the cotter pin (2).
together.
20. Adjust the brake as described in paragraph 6-1.
17. Assemble the lock washers (31) and nuts (19) to
the bolts. (20). 21. Install the service cover.

18. Install the assembled brake (18) to mounting plate 22. Remove the restrictions from the steering arm.
with two screws (10) and lockwashers (9). Tap 23. Reconnect battery connections.

R6110

Figure 6-3 Parts Replacement

PDI0404 6-3
 NOTES

6-4 PDI0404
 SECTION 7
TRANSMISSION, DRIVE WHEEL, ADJUSTABLE STRADDLE,
AND LOAD WHEEL SERVICING

Completing the initial disassembly procedure provides NOTE: During reassembly, inspect parts for wear and
access to any transmission parts requiring replace- replace as required. Be sure that washers (34
ment. Be sure to observe the notes. and 35), seal (36), bearings (37) and spacer
(38) are reinstalled in proper sequence as
7-1. INITIAL DISASSEMBLY shown in Figure 7-1.

NOTE: Refer to Figure 7-1 for the following proce- 7-3. REMOVAL OF MOTOR AND BRAKE
dure. ASSEMBLY INCLUDING DRIVE GEAR.
1. Disconnect battery. 1. Perform steps 1. through 4. of initial disassembly
2. Securely block load wheels. (paragraph 7-1.).
3. Remove service cover. NOTE: To remove brake pad assembly refer to SEC-
TION 6, Brake Servicing.
NOTE: Transmission holds 4-1/2 pints of transmis-
sion oil. 2. Make sure the four cables to the drive motor (1,
Figure 7-1) are properly labeled A1, A2, F1, and
4. Remove magnetic drain plug (19, Figure 7-1) and
F2; then disconnect the cables from the drive
drain transmission oil into a suitable container.
motor.
5. Turn steering arm to gain access to cover (43).
3. Remove the four bolts (2, Figure 7-1) and lock
6. Remove fourteen screws (45) and lock washers washers (3) that secure the motor mounting plate
(46) securing cover (43), then remove cover. (4) to the transmission housing (49).
7. Remove and discard gasket (42). 4. Tap motor mounting plate loose and remove
8. Remove thrust washer (29), gear (28), and key mounting plate with motor (1), disc assembly (7),
(51). bearing (8), O-ring (9), and gear (53) as a single
unit.
NOTE: When reassembling, be sure to replace the
5. To remove motor bearing housing (10), remove
gasket and reinstall the magnetic drain plug
two hex head screws (15) securing motor bearing
before refilling the transmission with transmis-
housing to transmission housing (49).
sion oil. Transmission holds 1-1/2 quarts oil.
6. Remove motor bearing housing along with O-ring
7-2. DRIVE AXLE AND WHEEL REMOVAL. (11) and seal (12).

NOTE: Refer to Figure 7-1 for the following proce- NOTE: During reassembly, inspect parts for wear and
dure. replace as required. Be sure that dowel pins
(13) in motor mounting (4) plate are aligned
1. Perform initial disassembly procedure (paragraph with corresponding holes in transmission
7-1.). housing (49).
2. Raise the rear of the truck using jacks or other
suitable means so that drive wheel is off the floor. 7-4. REMOVAL OF BRAKE DISC ASSEMBLY.
3. Remove snap ring (41), gear (40), and key (39), 1. Remove the motor and brake assembly, including
then pull out shaft (33) and wheel (17). Washers drive gear, as outlined in paragraph 7-3.
(34 and 35), bearings (37), spacer (38), and seal 2. To remove gear (53, Figure 7-1) from armature
(36) will fall free. shaft of motor (1), remove roll pin (54), then slide
4. To remove wheel (17) from shaft (33), remove five gear off of armature shaft.
bolts (18). 3. Remove O-ring (9) and bearing (8) from armature
shaft of motor (1).
4. Remove key (6) from armature shaft.

PDI0404 7-1
 R3851

Figure 7-1 Transmission

7-2 PDI0404
5. Remove disc assembly (7) from armature shaft of 1. Set brake in locked position.
motor.
CAUTION: Do not raise truck higher than necessary
NOTE: During reassembly, inspect parts for wear and for load wheels to clear floor when per-
replace as required. Be sure bearing (8), O- forming next step or truck can flip over.
rings (9 and 11) and seal (12) are reinstalled
in proper sequence as shown in Figure 7-1. 2. Raise one side of frame just enough for the strad-
dle load wheel to clear the ground.
7-5. ADJUSTABLE STRADDLE LIFT TRUCKS. 3. Remove two bolts (4, Figure 7-2) and two wash-
ers (3) from raised side of lift truck.
Parts on the adjustable straddle lift trucks are identical
to the fixed straddle except for the removable straddle 4. Slide straddle to dimension desired.
and the attaching hardware as shown in Figure 7-2.
NOTE: Minimum spread of straddle legs is 38 inches
Perform the following procedure to adjust the straddles
and maximum spread is 50 inches.
to a desired width.
5. Lubricate and reinstall two washers (3) and two
bolts (4).

NOTE: Retighten bolts to 200 ft.-lbs.

CAUTION: All bolts must engage straddles and both

straddles must be adjusted with equal
number of holes exposed on each side.

6. Lower straddle to the floor and raise the other side

just enough to clear straddle load wheels from the
floor.
7. Repeat steps 3. through 5.
8. Lower truck straddle to the floor.
9. Recheck that both straddles are adjusted with
equal number of holes exposed on each side.
R3828

Figure 7-2 Adjustable Straddle Frame

PDI0404 7-3
7-6. LOAD WHEELS.

NOTE: Refer to Figure 7-3 for the following proce-

dure.

1. Block the caster wheels and remaining load wheel

securely, and set the brakes.
2. Raise front end of lift truck with a jack or another
lift truck. Place strong supports under straddle leg
immediately in back of wheel housing so that the
load wheel being replaced is held approximately
one inch from the floor.
3. Remove the two snap rings (1, Figure 7-3) secur-
ing the load wheel axle (3).
4. Remove roll pin (8), then remove axle. Load
wheel (4) will drop free, along with two spacers
(2), one on each side, which position wheel on
axle.
5. Remove bearing (5) and two retaining washers
(6).
6. Clean and check bearing for defects. Replace
bearing if defective.
7. Lubricate bearing.
8. Reinstall bearing (5) with two retaining washers LOAD WHEEL AND AXLE KIT
(6) and two spacers (2) into load wheel (4). PART NUMBER 901326
9. Position load wheel (4) in straddle leg with axle CONTAINS:
holes aligned. ITEM QTY
10. Install axle (3) through straddle leg and load 1 2
wheel. 2 2
3 2
11. Install roll pin (8) through roll pin hole in axle.
7 1
12. Install snap rings (1) on both end of axle. 8 1
13. Lubricate axle through grease fitting (7).
R1756
14. Remove supports from under straddle leg, lower
front end of lift truck, remove wheel blocks, and Figure 7-3 Load Wheels
release brakes.

7-4 PDI0404
 SECTION 8
ELEVATION SYSTEM SERVICING

8-1. GENERAL. 3. Take up slack in both lift chains with hex nut (20,
The elevation system includes the outer mast, inner Figure 8-1, Figure 8-2 or 21, Figure 8-3) on the
mast (telescopic and full free lift models), lift carriage, adjusting bolt. Strive for equal tension on chains.
lift chains, lift cylinder, and ram head. 4. Align adjusting bolts so each clevis pin is parallel
to ram head (25, Figure 8-1, Figure 8-2 or 5, Fig-
8-2. LIFT CHAIN LENGTH ADJUSTMENT. ure 8-3).

8-2.1. Telescopic and Non-Telescopic. CAUTION: At least 3 full threads must be present
below hex nut (20, Figure 8-1, Figure 8-2
1. Lower carriage (34, Figure 8-1, Figure 8-2 or 25,
and 21, Figure 8-3) after completion of
Figure 8-3) fully, then disconnect battery.
adjustment.
WARNING: Before attempting any adjustment, make
5. Tighten jam nuts securely while maintaining align-
certain power is disconnected.
ment of adjusting bolts.
2. Loosen top jam nuts (18, Figure 8-1, Figure 8-2 or 6. Reconnect battery.
19, Figure 8-3) on adjusting bolts (17, Figure 8-1, 7. Test chain by operating carriage. If slack is still
Figure 8-2 or 18, Figure 8-3). apparent, repeat above procedure.

USED ON TRUCKS
SERIAL NUMBERS
338206 TO 376499

R5822

Figure 8-1 Elevation System (Telescopic)

PDI0404 8-1
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 338205

R5829

Figure 8-2 Elevation System (Telescopic)

8-2.2. Full Free Lift. 7. Test chain by operating carriage. If slack is still
1. Lower carriage (31, Figure 8-4) fully, then discon- apparent, repeat above procedure.
nect battery.
8-3. LIFT CHAIN WEAR INSPECTION
WARNING: Before attempting any adjustment, make Both lift chains should be replace when either chain is
certain power is disconnected. worn enough to increase it’s length by 3% or more. To
2. Loosen top jam nuts (28) on adjusting bolts (27). make this determination proceed as follows.

3. Take up slack in both lift chains with hex nut (30) Using a section of chain that sees the most frequent
on the adjusting bolt. Strive for equal tension on operation over the chain sheaves, isolate a vertical
chains. portion under tension from the weight of carriage and
forks.
CAUTION: At least 3 full threads must be present
Measure the distance between pin centers on 20 verti-
below hex nut (30) after completion of
cal links. If the section measures 12.88” or more, the
adjustment.
chain should be replaced.
4. Align adjusting bolts so each clevis pin is parallel New chain anchor pins should be installed when
to sheave (24). chains are replaced. Never replace a partial section of
5. Tighten jam nuts securely while maintaining align- chain and never repair a damaged chain. Refer to
ment of adjusting bolts. paragraph 8-4. when installing new chain.
6. Reconnect battery.

8-2 PDI0404
 R1752

Figure 8-3 Elevation System (Non-Telescopic)

8-4. LIFT CHAIN REPLACEMENT. 4. Remove cotter pin (16, Figure 8-1, Figure 8-2 or
17, Figure 8-3) and clevis pin (14, Figure 8-1, Fig-
8-4.1. Telescopic and Non-Telescopic. ure 8-2 or 16, Figure 8-3) from chain adjusting
1. Place a solid block on floor under the vertical bolt (17, Figure 8-1, Figure 8-2 or 18, Figure 8-3).
members nearest the center of the lift carriage. 5. Remove chain from ram head assembly (25, Fig-
2. Lower carriage until it is supported by the block ure 8-1, Figure 8-2 or 5, Figure 8-3) and lay aside
and the load chains are slack, then disconnect for repair.
battery. 6. Position new chain in place on ram head assem-
bly.
WARNING: Before attempting any actual replace-
ment, make certain power is discon- 7. Install cotter pin and clevis pin on chain adjusting
nected. bolt.
8. Connect end of chain to mast cross brace with
3. Remove cotter pin (16, Figure 8-1, Figure 8-2 or
cotter pin and clevis pin.
17, Figure 8-3) and clevis pin (14, Figure 8-1, Fig-
ure 8-2 or 16, Figure 8-3) from end of chain con- 9. Adjust chain according to paragraph 8-2.
nected to mast cross brace.

PDI0404 8-3
 R5830

Figure 8-4 Elevation System (Full Free Lift)

8-4 PDI0404
8-4.2. Full Free Lift. 8. Remove cap screw and lock washer (3 and 4) and
lift ram head (5) from lift cylinder (1).
1. Place a solid block on floor under the vertical
members nearest the center of the lift carriage. 9. Remove screw (15), lock washer (12) and plain
2. Lower carriage until it is supported by the block washer (14) from base of cylinder (1).
and the load chains are slack, then disconnect WARNING: Support lift cylinder before performing
battery. step 10. to prevent cylinder from falling.
WARNING: Before attempting any actual replace- 10. Remove nuts (11) and lock washers (12) that
ment, make certain power is discon- secure clamp (13) and remove clamp.
nected.
11. Raise lift cylinder assembly up and out of truck.
3. Remove cotter pin (16, Figure 8-4) and clevis pin
NOTE: Disassembly of lift cylinder is covered in SEC-
(17) from end of chain connected to lift cylinder.
TION 9.
4. Remove cotter pin (16) and clevis pin (17) from
chain adjusting bolt (27). 12. Reinstall lift cylinder in reverse order of removal.
5. Remove chain from sheave (24) and lay aside for 13. Adjust chain according to paragraph 8-2.
repair.
8-5.2. Telescopic.
6. Position new chain in place on sheave (24).
7. Install clevis pin (17) and cotter pin (16) on chain NOTE: Refer to Figure 8-1 or Figure 8-2 for the fol-
adjusting bolt (27). lowing procedure.

8. Connect end of chain to lift cylinder (15) with cle- 1. With the lift truck wheels securely blocked and
vis pin (17) and cotter pin (16). with brake set, raise forks approximately three
9. Adjust chain according to paragraph 8-2. feet from floor and position blocks or strong sup-
ports under inner mast (1, Figure 8-1 or Figure 8-
8-5. LIFT CYLINDER REMOVAL. 2).
2. Lower inner mast onto support. Check that
8-5.1. Non-Telescopic. arrangement is secure before proceeding.
NOTE: Refer to Figure 8-3 for the following proce- 3. Disconnect battery.
dure. 4. Remove two cap screws (33), two lock washers
1. With the brake set and the lift truck wheels (22) one cap screw (31) and one lock washer (32)
securely blocked, raise forks approximately three that join the top of the inner mast (1) to the ram
feet from floor and position blocks or strong sup- head (25).
ports under lift carriage (25, Figure 8-3). 5. Hold lift control lever forward and, at the same
time, manually push the ram down as far as possi-
2. Lower lift carriage fully onto support.
ble. The chains will become slack and need not
3. Disconnect battery. be removed.
4. Hold lift control lever forward and, at the same 6. Remove overflow tubing retainers alongside of the
time, manually push lift cylinder ram (5) down as lift cylinder assembly (24).
far as possible.
WARNING: Before disconnecting any hydraulic line,
5. Remove overflow tubing retainers along the side
be sure the system is not under pres-
of the lift cylinder assembly (1).
sure.
WARNING: Before disconnecting any hydraulic line,
be sure the system is not under pres- 7. Disconnect hose assembly from bottom of lift cyl-
sure. inder. Disconnect overflow tubing from top of lift
cylinder (24).
6. Disconnect hose assembly from bottom of lift cyl- 8. Lift chains clear of sheaves (27) and lay them
inder and overflow tubing from top of lift cylinder. aside.
7. Lift chains clear of sheaves (7) and lay chains 9. Remove screw (21), lock washer (22) and plain
aside. washer (23) from underside of cylinder.

PDI0404 8-5
WARNING: Support lift cylinder before performing 10. Remove the yoke sheaves as described in para-
the following steps to prevent cylinder graph 8-7.
from falling.
NOTE: Disassembly of lift cylinder is covered in SEC-
10. Tilt lift cylinder (24) and ram head (25) forward TION 9.
from their position in the lift truck.
11. Reinstall lift cylinder in reverse order of removal.
11. Lift ram head from lift cylinder.
12. Adjust chain according to paragraph 8-2.
12. Raise lift cylinder assembly up and out of truck.

NOTE: Disassembly of lift cylinder is covered in SEC- 8-6. RAM HEAD REMOVAL.
TION 9. WARNING: Make certain power is disconnected
13. Reinstall lift cylinder in reverse order of removal. before attempting to remove ram head.

14. Adjust chain according to paragraph 8-2. 8-6.1. Non-Telescopic.

8-5.3. Full Free Lift. NOTE: Refer to Figure 8-3 for the following proce-
dure.
NOTE: Refer to Figure 8-4 for the following proce-
dure. 1. With the brake set and the lift truck wheels
securely blocked, lower the lift carriage fully, then
1. Fully lower the lift carriage. disconnect battery.
2. Disconnect battery. 2. Slacken the lift chains by loosening the nut (19,
WARNING: Before disconnecting any hydraulic line, Figure 8-3) below the chain adjusting bolt (18).
be sure the system is not under pres- Then lift chains off sheaves and lay them on mast
sure. support.
3. Remove cap screw (3) and lockwasher (4) and lift
3. Disconnect hose at the bottom of the lift cylinder. ram head assembly (5) from lift cylinder (1).
4. Remove connector, flow control valve, elbows and
nipple at the bottom of the lift cylinder. 8-6.2. Telescopic.
5. Using another lift truck or suitable jack, raise lift NOTE: Refer to Figure 8-1 or Figure 8-2 for the fol-
carriage far enough to remove chains from around lowing procedure.
sheaves (24). Lay chains aside and lower lift car-
riage. 1. With the lift truck wheels securely blocked and
with brake set, raise forks approximately three
6. Remove screw (3), lock washer (7), and flat feet from floor and position blocks or strong sup-
washer (8) securing the top of lift cylinder (15) to ports under inner mast (1, Figure 8-1 or Figure 8-
the inner mast (11). 2).
7. Remove screw (3), lock washer (4), and flat
2. Lower inner mast onto support. Check that
washer (10) securing the bottom of lift cylinder
arrangement is secure before proceeding.
(15) to the outer mast.
3. Disconnect battery.
WARNING: Lift cylinder must be supported during 4. Remove two cap screws (33), two lock washers
the next step. (22) one cap screw (31) and one lock washer (32)
8. Support lift cylinder and using another lift truck or that join the top of the inner mast (1) to the ram
suitable jack, raise inner mast (11) far enough to head (25).
clear top of lift cylinder. 5. Hold lift control lever forward and, at the same
9. Lift cylinder up and out of truck. time, manually push the ram down as far as possi-
ble. The chains will become slack.
6. Lift ram head (25) from lift cylinder (24).

8-6 PDI0404
8-7. YOKE SHEAVE REPLACEMENT (FULL FREE 8. Adjust lift chains as described in paragraph 8-2.
LIFT).
8-8. LUBRICATION OF MAST.
WARNING: Make certain power is disconnected
before attempting to remove ram head. NOTE: Refer to Figure 8-1, Figure 8-2 and
Figure 8-3.
1. Lower the lift carriage fully.
2. Disconnect the battery. Fully lower lift carriage, then apply a (Lithium base)
general purpose grease, using a lubrication gun, to the
3. Slacken the lift chains by loosening nut (30, Fig- following components:
ure 8-4) below adjusting bolt (27) on the lift car-
riage. 1. Grease fittings (10, Figure 8-3) on lift carriage roll-
ers (22) and sheaves (7).
4. Lift the lift chains off sheaves (24) and lay on the
mast support. 2. Grease fittings (30, Figure 8-1 or Figure 8-2) on
sheaves (20).
5. Remove snap ring (19) and slide pin (20) out of
sheave (24). Sheave (24), bearing (23), and thrust Using a brush, apply the same Lithium base general
washers (22) will fall free. purpose lubricant to the full length of the mast channel
where the rollers ride. Upon completion, operate the
6. Yoke sheave (26) can now be removed by remov-
mast to allow lubricant to spread evenly.
ing screws (21).
7. Reinstall yoke sheave in reverse order of removal.

PDI0404 8-7
 NOTES

8-8 PDI0404
 SECTION 9
HYDRAULIC SYSTEM SERVICING

9-1. RELIEVING SYSTEM PRESSURE. 9-2. FLOW CONTROL VALVE REPLACEMENT.

WARNING: Hydraulic system pressure must be NOTE: Figure 9-2 and Figure 9-3 show the relation-
relieved before removing hydraulic sys- ship of all components in the hydraulic sys-
tem components. Use the following pro- tem. Refer to these figures for the following
cedure to relieve system pressure: procedure.

1. Lower the lift carriage fully. 1. With the lift truck wheels securely blocked and
2. Obtain a suitable container to catch any oil that with the brake set, raise forks approximately three
may escape when opening a line. feet from floor. Position blocks or strong supports
under the inner mast (on telescopic model) or
3. Open the low pressure line at any convenient con- under lift carriage (on non telescopic model) while
nection near the component that is to be repaired hydraulic system is under repair.
or replaced.
2. Lower inner mast or lift carriage onto supports.
NOTE: A schematic diagram of the hydraulic system Check that the arrangement is secure before pro-
is shown in Figure 9-1. ceeding.
3. Disconnect battery.

R3830

Figure 9-1 Hydraulic System Schematic

PDI0404 9-1
 R1750

Figure 9-2 Hydraulic System (Telescopic and Non-Telescopic)

4. On telescopic models remove the two cap screws 9. Reconnect hose (17, Figure 9-2 or
and two lock washers securing the top of the inner 19, Figure 9-3).
mast to the ram head. 10. On telescopic models resecure ram head with the
5. Hold lift control forward, and at the same time two cap screws and lock washers.
manually push the ram of the lift cylinder down as 11. Reconnect battery.
far as possible. The chains will become slack and
need not be removed. 12. Check oil level on dip stick. If low, fill to ``FULL''
mark on dip stick with Big Joe hydraulic oil part
NOTE: A small amount of hydraulic oil will drain from number 900855.
the system when the hydraulic line is discon- 13. Raise forks, then remove supports.
nected. Use rags or suitable container to
catch the draining oil. 14. Check for leaks.

6. Disconnect hose (17, Figure 9-2 or 19, Figure 9- 9-3. SUCTION LINE FILTER REPLACEMENT.
3) and connector (27, Figure 9-2 or 33, Figure 9-
3) from flow control valve (28, Figure 9-2 or 31, NOTE: Refer to Figure 9-2 or Figure 9-3 for the fol-
Figure 9-3). lowing procedure.

7. Remove flow control valve. 1. Lower lift carriage fully to insure that all pressure
8. Install new flow control valve (28, Figure 9-2 or 31, is relieved from hydraulic system.
Figure 9-3) with direction arrow on flow control 2. Remove reservoir drain plug (19, Figure 9-2 or
valve pointing toward lift cylinder. 21, Figure 9-3), and drain oil into suitable con-
tainer.

9-2 PDI0404
 R5821

Figure 9-3 Hydraulic System (Full Free Lift)

PDI0404 9-3
3. Remove clamp (21, Figure 9-2 or 23, Figure 9-3) 6. Remove the reservoir vent cap, fill the reservoir to
and tubing (22, Figure 9-2 or 24, Figure 9-3) from the ``FULL'' mark on the dip stick, and replace the
filter (20, Figure 9-2 or 22, Figure 9-3). vent cap.
4. Unscrew filter from reservoir.
9-5. LIFT/LOWER CONTROL VALVE.
5. Install new filter on reservoir.
6. Install tubing (22, Figure 9-2 or 24, Figure 9-3) 9-5.1. Adjustment.
and clamp (21, Figure 9-2 or 23, Figure 9-3) onto
NOTE: The lift/lower control valve is properly
new filter.
adjusted, inspected, and checked thoroughly
7. Clean the drain plug (19, Figure 9-2 or 21, Figure before leaving the factory. The valve should
9-3) thoroughly. rarely need readjusting; but if adjustment is
8. Re-install the drain plug. necessary, the following procedure should be
used to set the valve for lowering and the
NOTE: Refill only with Big Joe hydraulic oil part num- hydraulic pump switch for lifting.
ber 900855 and only while carriage is fully
lowered. Refill until oil is to the ``FULL'' mark NOTE: Refer to Figure 9-4, Figure 9-5 and Figure 9-6
on the dip stick. Reservoir holds about 1-1/2 for the following procedure.
gallons of oil.
1. Raise lift carriage part way with a moderate load
9. Remove reservoir vent cap, fill reservoir to on the forks to build up pressure in the hydraulic
``FULL'' mark on the dip stick, and replace vent system.
cap. CAUTION: Prevent lift control valve clamp (8, Figure
9-5 or Figure 9-6) from slipping off the
9-4. LINE OR FITTING REPLACEMENT. release cam (3), or the handle return
WARNING: Lift carriage must be fully lowered before spring (7) will slip by the roll pins (6).
performing maintenance on the hydraulic
2. Loosen upper nut (9, Figure 9-5 or Figure 9-6) on
system.
lift control valve clamp (8).
NOTE: Leaking hydraulic fittings can sometimes be 3. Using the point where the lift control knob and
remedied by simply tightening the fitting. If handle come together as a reference point, push
this does not remedy the leak, the fitting or handle forward 3/4 inch from neutral position (see
line must be replaced. Figure 9-4).
1. Lower lift carriage fully.

CAUTION: Hydraulic oil can dissolve the battery

case. Wipe off any spilled oil immedi-
ately.

2. Remove the reservoir drain plug and drain the

hydraulic oil into a suitable container.
3. Remove the leaking line or fitting and replace it
with a new one.
4. Clean the drain plug thoroughly.
5. Re-install the drain plug.

NOTE: Refill only with Big Joe hydraulic oil part

number 900855 and only while the carriage
is fully lowered. Refill until oil is to the ``FULL''
mark on the dip stick. Reservoir holds about
1-1/2 gallons of oil.
R190

Figure 9-4 Lift/Lower Control Valve Adjustment

9-4 PDI0404
4. With a screwdriver in slot of release cam, rotate 1/ NOTE: Disconnecting of wires is not necessary.
8 turn clockwise. This is to make sure check ball is
seated in valve seat. 5. Disconnect tubing (22, Figure 9-2 or 15, Figure 9-
3) from lift/lower control valve (9, Figure 9-2 or 11,
5. With a screwdriver in slot of release cam, rotate Figure 9-3).
counterclockwise until a definite resistance is felt.
(Resistance is felt as the pin resting on check ball 6. Disconnect hose assemblies (17 and 18, Figure
pushes against the hydraulic pressure in system.) 9-2 or 20 and 30 Figure 9-3).
At this point release cam action has moved pin 7. Remove lift/lower control valve (9, Figure 9-2 or
(13, Figure 9-5 or Figure 9-6) down against check 11, Figure 9-3) complete with hydraulic fittings (10
ball (14). Rotation of release cam beyond this and 35, Figure 9-2 or 12 and 35, Figure 9-3) by
point pushes ball away from valve seat and opens removing the four screws (5, Figure 9-2 or 3, Fig-
system, allowing lift carriage to descend. ure 9-3) and lock washers (6, Figure 9-2 or 2, Fig-
6. Tighten upper nut (9). ure 9-3) securing the valve to the mounting
bracket (8, Figure 9-2 or 10, Figure 9-3).
9-5.2. Disassembly. 8. Remove hydraulic fittings.
WARNING: Before disconnecting any hydraulic line, 9. Loosen lower nut (9, Figure 9-5 or Figure 9-6)
be sure the system is not under pres- securing lift control handle (10) to valve clamp (8)
sure. and slide handle with clamp from release cam (3).
10. Remove handle return spring (7).
NOTE: Refer to Figure 9-2, Figure 9-3, Figure 9-5
and Figure 9-6 for the following procedure. 11. Remove two screws (5) securing switch bracket
(4) to valve body (1), then remove switch bracket.
1. Lower lift carriage fully.
12. The release cam (3) and O-ring (2) can now be
2. Disconnect battery. pulled from the valve body (1).
3. Hold lift/lower control forward and, at the same
NOTE: Install new parts as required during reassem-
time, manually push the ram of the lift cylinder
bly of the lift control valve.
down as far as possible.
4. Remove pump motor switch (12, Figure 9-5 or
Figure 9-6) and lay aside.

R1809 R1755

Figure 9-5 Lift/Lower Control Valve (Standard) Figure 9-6 Lift/Lower Control Valve
(Cold Conditioning)

PDI0404 9-5
13. To reassemble, install O-ring (2, Figure 9-5 or Fig- 9-6.1. Pump and Motor Assembly Removal.
ure 9-6) and release cam (3) onto valve body (1).
WARNING: Before disconnecting any hydraulic lines,
14. Install switch bracket (4) onto valve body (1) with make sure the forks are lowered com-
two screws (5). pletely and the system is not under pres-
15. Install handle return spring (7) onto release cam sure.
(3).
NOTE: See Figure 9-2 or Figure 9-3 for the following
16. Install valve clamp (8) with handle (10) onto procedure.
release cam (3) and tighten lower nut (9).
17. Install hydraulic fittings (10 and 35, Figure 9-2 or 1. Disconnect battery.
12 and 35, Figure 9-3) onto control valve (9, Fig- 2. Drain hydraulic oil from reservoir into suitable con-
ure 9-2 or 11, Figure 9-3). tainer.
18. Install lift/lower control valve (9, Figure 9-2 or 11, 3. Label, then disconnect wires from solenoid.
Figure 9-3) onto mounting bracket (8, Figure 9-2 4. Label, then disconnect tubing (22, Figure 9-2 or
or 10, Figure 9-3) with four lock washers (6, Fig- 24, Figure 9-3) and hose (18, Figure 9-2 or 20,
ure 9-2 or 2, Figure 9-3) and four screws (5, Fig- Figure 9-3) from the pump (26, Figure 9-2 or 27,
ure 9-2 or 3, Figure 9-3). Figure 9-3).
19. Reconnect hose assemblies (17 and 18, Figure 9- 5. Remove the pump and motor assembly by remov-
2 or 20 and 30, Figure 9-3) to hydraulic fitting (35, ing the two hex head screws securing the assem-
figure 9-2 or 17, Figure 9-3). bly, then lift the assembly from the mounting
20. Reconnect tubing (22, Figure 9-2 or 15, Figure 9- bracket.
3) to control valve. 6. To separate the pump from the motor, remove the
21. Install pump motor switch (12, Figure 9-5 or Fig- four hex head screws and four lock washers that
ure 9-6) onto switch bracket (4). connect the pump to the motor end housing.
22. Reconnect battery. NOTE: When reassembling the pump to the motor,
always use a new gasket.
9-5.3. Pump Motor Switch Adjustment.
When the release cam (3, Figure 9-5 or Figure 9-6) is 9-6.2. Hydraulic Pressure Adjustment.
properly set, it may be necessary to readjust the
hydraulic pump motor switch (12). For proper switch WARNING: Improper setting of the hydraulic pump
action and precise control of the lift carriage, a clear- pressure by an unauthorized person can
ance of approximately 0.010 inch should be main- damage the hydraulic system and void
tained between the switch actuator button and the lift your warranty.
control valve clamp (8). NOTE: The hydraulic pump is factory set to lift a load
1. To adjust the pump motor switch for proper clear- at the rated capacity of the truck. The pres-
ance, loosen the two nuts holding the switch in the sure relief valve should rarely need adjust-
switch bracket. ment. If the truck fails to lift a load that is
within the truck capacity rating, adjust as fol-
2. Raise or lower the position of the switch by turning
lows:
the upper nut.
3. When there is a 0.010 inch clearance between the 1. Remove the cap nut from the hydraulic pump.
switch actuator button and lift control valve clamp, 2. Insert a screwdriver blade in the screw slot.
tighten the lower nut against the bracket to lock
the switch in place. CAUTION: Do not set pressure any higher than that
required to lift a load of the rated capac-
9-6. HYDRAULIC PUMP AND MOTOR ASSEMBLY. ity of the truck.
A defective hydraulic pump must be replaced as a 3. Turn the screwdriver clockwise to increase
complete unit, but the pump motor can be repaired hydraulic pressure; counterclockwise to decrease
(see SECTION 10, Electrical Components Servicing. pressure.
4. Install the cap nut on the hydraulic pump.

9-6 PDI0404
9-7. LIFT CYLINDER REPAIR. 9-7.2. Telescopic.

9-7.1. Non-Telescopic. NOTE: Removal procedures are covered in SEC-

TION 8.
NOTE: Removal procedures are covered in SEC-
TION 8. CAUTION: To prevent cylinder damage, use proper
pipe clamp vise. The cylinder will be dis-
CAUTION: To prevent cylinder damage, use proper torted if the vise is tightened too much.
pipe clamp vise. The cylinder will be dis-
torted if the vise is tightened too much. 1. Secure lift cylinder assembly in a vise and remove
gland nut (3, Figure 9-8) with wiper ring (2) and O-
1. Secure lift cylinder assembly in a vise and remove ring (4).
gland nut (3, Figure 9-7) with wiper ring (2) and O-
2. Pull out cylinder ram (5).
ring (4).
3. Remove lift cylinder tube (1) from vise.
2. Pull out cylinder ram (5).
3. Remove lift cylinder tube (1) from vise. CAUTION: To prevent damaging the finish on the
ram, use proper pipe clamp vise with
CAUTION: To prevent damaging the finish on the non-marring jaws.
ram, use proper pipe clamp vise with
non-marring jaws. 4. Secure ram (5) in vise.
5. Remove nut (11).
4. Secure ram (5) in vise.
6. Cylinders equipped with piston (8), pull off
5. Remove nut (11) washers (10 and 13), packing assembly (9), pis-
6. Cylinders equipped with piston (8), pull off ton (8) and O-ring (7).
washers (10 and 13), packing assembly (9), pis-
ton (8) and O-ring (7). Cylinders equipped with piston (14), pull off
piston (14) and O-ring (7). Remove seal (15) from
Cylinders equipped with piston (14), pull off piston (14).
piston (14) and O-ring (7). Remove seal (15) from NOTE: Cylinders equipped with piston (8 or 16),
piston (14). install retrofit kit 907139.
NOTE: Cylinders equipped with piston (8), install ret- NOTE: Cylinders equipped with piston (14), install
rofit kit 907124. packing kit 907138.
NOTE: Cylinders equipped with piston (14), install 7. Coat seal (15) and piston (14) liberally with petro-
packing kit 907123. leum jelly. Install new seal (15) on piston (14).
7. Install new O-ring (7), piston (14), new seal (15), 8. Install new O-ring (7), piston (14), and nut (11)
and nut (11) onto cylinder ram (5). onto cylinder ram (5).
8. Remove cylinder ram (5) from vise. 9. Remove cylinder ram (5) from vise.

CAUTION: To prevent cylinder damage, use proper CAUTION: To prevent cylinder damage, use proper
pipe clamp vise. The cylinder will be dis- pipe clamp vise. The cylinder will be dis-
torted if the vise is tightened too much. torted if the vise is tightened too much.

9. Secure lift cylinder tube (1) in vise. 10. Secure lift cylinder tube (1) in vise.
10. Install cylinder ram (5) into cylinder tube (1). 11. Install cylinder ram (5) into cylinder tube (1).
11. Install new O-ring (4), and gland nut with new 12. Install new O-ring (4) and wiper ring (2) on gland
wiper ring (2). nut (3).
13. Install gland nut (3) in cylinder tube (1).
12. Remove lift cylinder assembly from vise.
14. Remove lift cylinder assembly from vise.

PDI0404 9-7
 RETROFIT KIT PACKING KIT
PART NUMBER PART NUMBER
907124 CONTAINS: 907123 CONTAINS:
ITEM QTY ITEM QTY
2 1 2 1
4 1 4 1
7 1 7 1
11 1 11 1
14 1 15 1
15 1

USED ON TRUCKS
SERIAL NUMBERS
333375 TO 338205
R6107

R6106

Figure 9-7 Lift Cylinder (Non-Telescopic)

9-8 PDI0404
 PACKING KIT
USED ON TRUCKS PART NUMBER
SERIAL NUMBERS 907123 CONTAINS:
333375 TO 353212
ITEM QTY
2 1
4 1
7 1
11 1
15 1

RETROFIT KIT
PART NUMBER
907124 CONTAINS:
ITEM QTY
2 1
4 1
7 1
11 1
14 1
15 1

R5812

Figure 9-8 Lift Cylinder (Telescopic)

PDI0404 9-9
9-7.3. Full Free Lift. 7. Assemble FFL center cylinder by reversing the
disassembly procedure. For ease of assembly
NOTE: Removal procedures are covered in SEC- when assembling threaded parts, apply a coating
TION 8. of white lead replacement to the threads--except
CAUTION: To prevent cylinder damage, use proper for the threads of the cylinder base (9) which are
pipe clamp vise. The cylinder will be dis- to be coated with Loctite 222 adhesive (24).
torted if the vise is tightened too much. 8. If either or both of the outer cylinders of FFL cylin-
der assembly must be repaired, proceed as fol-
1. Secure lift cylinder weldment (1, Figure 9-9) in lows:
vise and remove the snap ring retainer (3) and
square head pipe plug (2). CAUTION: As cylinder rod of either outer cylinder is
2. Pull outward on the cylinder base (9) until wear pulled out of cylinder tube, the two
ring (14) contacts the cylinder base. Continued halves of wear ring (22) may fall free and
pulling will bring the cylinder head (4) out of the be damaged hitting the floor. Be sure to
tube. catch these pieces.

3. Use a strap wrench to hold the cylinder rod (13) a. Remove snap ring retainer (15).
and unscrew cylinder base (9) from cylinder rod.
b. Pull outward on the cylinder rod (23) until
Remove cylinder head (4) from cylinder rod.
wear ring (22) pushes cylinder head (16) out
CAUTION: As cylinder rod (13) is pulled out of cylin- of cylinder tube.
der tube, catch the two halves of wear c. A little more pulling will release the halves of
ring (14) which will be freed and may fall the wear ring.
and be damaged.
d. Catch these pieces for reuse if in good condi-
4. The cylinder rod (13) may now be pulled out of the tions.
tube. Support it carefully and catch the two halves e. Carefully support cylinder rod (23) and pull it
of the wear ring (14) as they are free. Continue to outward to free it and piston (20) from the
pull on the cylinder rod until the piston (12) is out tube. If the piston is worn or damaged, or to
of the tube. replace "O" ring (21), hold the rod with a
5. If piston is worn or damaged hold the cylinder rod strap wrench and remove Flexloc lock nut
(13) with a strap wrench and take off Flexloc lock (11) and pull piston free of rod.
nut (11). Pull piston free of the rod.
f. Examine bore of cylinder tube being
6. Examine bore of center cylinder tube of the cylin- repaired, surface of cylinder rod (23) and
der assembly (1), and surfaces of the cylinder rod wear ring halves (22) for scoring, scratching,
(13), piston (12), and wear ring halves (14). or other damage.
Replace all unsatisfactory parts and proceed with
g. Replace all unsatisfactory parts and proceed
the following steps:
with the following steps:
a. Remove hydraulic cylinder wiper ring (7) and
(1) Remove and discard "O" ring (21) and
"U"-cup rod seal (8) from inside of cylinder
"U" cup seal (19).
head (4), and "O" ring (5) and back-up ring
(6) from outside of cylinder head. (2) Clean all parts and replace all "O" rings
and seals during reassembly.
b. Clean and dry all parts.
c. Discard all used "O" rings and seals and CAUTION: Reassembly of the lift cylinder requires
replace them with new ones during reassem- the use of special tool, part number
bly. 900931, to prevent damage to cylinder
packing.
d. Coat all new "O" rings and seals with hydrau-
lic fluid during reassembly. (3) Insert special tool part number 900931,
into the end of the cylinder, as shown in
Figure 9-9 (inset).

9-10 PDI0404
 (4) Coat rings and seals with hydraulic fluid (5) Assembly FFL outer cylinder(s) by
during replacement. reversing the disassembly procedure.
For ease of assembly, when assembling
threaded parts, apply a coating of white
lead replacement to the threads.

PACKING KIT
PART NUMBER
900949 CONTAINS:
ITEM QTY
5 1
6 1
7 1
8 1
10 1
17 2
19 2
21 2
R1583

Figure 9-9 Lift Cylinder (Full Free LIft)

PDI0404 9-11
 NOTES

9-12 PDI0404
 SECTION 10
ELECTRICAL COMPONENTS

10-1.ELECTRICAL CONTROL PANELS. 10-2.CONTROL PANEL SERVICING.

Truck Serial Number 333375 to 364407:
Figure 10-1 identifies parts associated with the com-
1. SEE SUPPLEMENT 187 FOR TRANSISTOR
plete electrical control panel assembly.
CONTROLLER USED ON TRUCKS SERIAL
NUMBER 333375 TO 338589 Truck Serial Number 364408 To 376499:
Figure 10-2 identifies parts associated with the com-
2. SEE SUPPLEMENT 233 FOR TRANSISTOR
plete electrical control panel assembly.
CONTROLLER USED ON TRUCKS SERIAL
NUMBER 338590 TO 372811 11. Secure moving contact (8) to armature (9) with
spring (6) and spring stud (7).
3. SEE SUPPLEMENT 349 FOR TRANSISTOR
CONTROLLER USED ON TRUCKS SERIAL
NUMBER 372812 TO 376499

USED ON TRUCKS 1. SEE SUPPLEMENT 187 FOR TRANSISTOR

SERIAL NUMBERS CONTROLLER USED ON TRUCKS SERIAL
333375 TO 364407 NUMBER 333375 TO 338589
2. SEE SUPPLEMENT 233 FOR TRANSISTOR
CONTROLLER USED ON TRUCKS SERIAL
NUMBER 338590 TO 364407

R3836

Figure 10-1 Electrical Control Panel

PDI0404 10-1
 1. SEE SUPPLEMENT 233 FOR TRANSISTOR USED ON TRUCKS
CONTROLLER USED ON TRUCKS SERIAL SERIAL NUMBERS
NUMBER 364408 TO 372811 364408 TO 376499

2. SEE SUPPLEMENT 349 FOR TRANSISTOR

CONTROLLER USED ON TRUCKS SERIAL
NUMBER 372812 TO 376499

R6083

Figure 10-2 Electrical Control Panel

10-2 PDI0404
10-3.Contactor Servicing. Serial Number 333375 to 7. Coil can now be removed from frame (2) by
364407. removing 3/4 inch long hex head screw and flat
washer.
NOTE: One contactor tip kit part number 900531-02
contains the number of contacts required to 10-3.2.2nd and 3rd Speed Contactor
service all contactors on a truck. Contactor tip Reassembly. (Refer to Figure 10-3)
kit part number 900531-09 contains contacts Serial Number 333375 to 364407
for the forward-reverse contactor. Contactor
tip kit part number 900531-08 contains con- 1. Place 1-1/4 inch long hex head bolt through bot-
tacts for the 2nd and 3rd speed contactors. tom of front molding (4) and slide molding onto
frame (2).
10-3.1.2nd and 3rd Speed Contactor 2. Attach coil (11) to frame (2) with flatwasher and 5/
Disassembly. (Refer to Figure 10-3) 8 inch long hex head bolt. Be sure braid assembly
Serial Number 333375 to 364407 (3) has been attached to frame (2) with 3/4 inch
bolt, flat washer, lock washer and nut. Use 10mm
NOTE: Order contactor tip kit part number 900531-
wrench on nut.
08. One kit repairs one 2nd or 3rd speed con-
tactor. 3. Attach frame (2) to base molding (1) by engaging
slots at bottom of frame (2) behind flanges near
1. Remove spring stud (7) and spring (6). lower edge of base molding (1).
2. Remove nut holding armature plate retainer (5) 4. Snap slots of top of front molding (4) into flanges
and remove retainer by squeezing in on tabs and of base (1). Coil assembly should now securely
lifting up. attach to base (1).
3. Slide braid assembly (3) off contact (8) and 5. Install spacer (13) in front molding (4) and install
remove contact (8) and armature plate (9) and front contact (12) secure with washer, lock washer
spring (6). and hex nut. Use 10 mm wrench on nut.
4. Use a 10 mm wrench to remove nut and flat 6. Place contactor on work surface with base mold-
washer holding front contact (12) and remove ing down. Place spring (6) on center of pole piece
contact. (10).
NOTE: If only contacts are to be replaced, no further 7. Position armature plate (9) against frame (2).
disassembly is required. Proceed to step 5. to 8. Place moving contact assembly (8) on armature
replace coil. plate then attach braid assembly (3) to contact
stud.
5. Remove spacer (13).
9. Place retainer (5) over contact stud and slip the
6. Squeeze sides of front molding (4) and pull for-
two tabs on retainer (5) into the two slots in arma-
ward to disengage from base molding (1).
ture plate (9). Secure with hex nut.
Remove base molding and remove front molding
from frame (2).

PDI0404 10-3
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 364407

CONTACTOR TIP KIT

PART NUMBER
900531-08 CONTAINS:
ITEM QTY
3 1
5 1
8 1
12 1

R1865

Figure 10-3 Contactor (2nd and 3rd Speed) Part Number 005659

10-3.3.Forward-Reverse Contactor Disassembly. 5. Slide braid assembly (3) off contact (8) and
(Refer to Figure 10-4) Serial Number 333375 remove contact (8) and armature plate (9) and
to 364407 spring (6).

NOTE: Order contactor tip kit part number 900531- 6. Use a 10 mm wrench to remove nut holding front
09. One kit repairs one contactor. Kit includes contact (12) and remove contact.
items (3, 5, 8, 12 and 16). NOTE: If only contacts are to be replaced, no further
1. Remove spring (7) and spring (6). disassembly is required. Proceed to step 7 to
replace coil.
2. Remove nut bolt and washer securing bus bar
(14), (if used) to back contact (16). 7. Remove spacer (13).
3. Slide back contact (16) up as far as possible then 8. Squeeze sides of front molding (4) and pull for-
squeeze sides of rear molding (17) together and ward to disengage from base molding (1).
lift off frame (2). Separate two sides of rear mold- Remove base molding and remove front molding
ing and remove back contact (16). from frame (2).
4. Remove nut holding armature plate retainer (5) 9. Coil can now be removed from frame (2) by
and remove retainer by squeezing in on tabs and removing 3/4 inch long hex head screw and flat
lifting up. washer.

10-4 PDI0404
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 364407

CONTACTOR TIP KIT

PART NUMBER
900531-09 CONTAINS:
ITEM QTY
3 1
5 1
8 1
12 1
16 1

R1866

Figure 10-4 Contactor (Forward-Reverse) Part Number 005657

10-3.4.Forward-Reverse Contactor Reassembly. 6. Place contactor on work surface with base mold-
(Refer to Figure 10-4) Serial Number 333375 ing down. Place spring (6) on center of pole piece
to 364407 (10).
1. Place 1-1/4 inch long hex head bolt through bot- 7. Position armature plate (9) against frame (2).
tom of front molding (4) and slide molding onto 8. Place moving contact assembly (8) on armature
frame (2). plate then attach braid assembly (3) to contact
2. Attach coil (11) to frame (2) with flat washer and stud.
5/8 inch long hex head bolt. Be sure braid assem- 9. Place retainer (5) on contact stud and slip the two
bly (3) has been attached to frame (2) with 3/4 tabs on retainer (5) into the two slots in armature
inch bolt, lock washer, flat washer and nut. Use 10 plate (9). Secure with hex nut.
mm wrench on nut.
10. Place two parts of back molding (17) together and
3. Attach frame (2) to base molding (1) by engaging slide contact (16) into slot in molding.
slots of bottom of frame (2) behind flanges near
11. Squeeze back molding together and place
lower edge of base molding (1).
grooves in back molding on frame (2). Push mold-
4. Snap slots at top of front molding (4) into flanges ing all the way down.
of base (1). Coil assembly should now be
12. Release back molding and press back contact
securely attached to base (1).
(16) down into position. Armature will need to be
5. Install spacer (13) in front molding (4) and install pressed down to position back contact.
front contact (12) secure with washer, lock washer
and hex nut. Use a 10 mm wrench on nut. 13. Reattach bus bar (14) (if used) to back contact
(16) using hex nut and washers.
14. Secure moving contact (8) to armature (9) with
spring (6) and spring stud (7).

PDI0404 10-5
10-4.PUMP MOTORS. 10-6.BATTERY CHARGER.
Refer to applicable Figure 12-29, Figure 12-30, Figure The PDI battery charger is mounted in the upper right
12-31 and Figure 12-32 for motor disassembly. Pumps side of the truck as shown in Figure 12-38 and Figure
are replaceable but not repairable. When replacing 12-39. Different chargers have been used on the PDI.
pump be sure to install the gasket between pump and Table 10-1 lists the different battery chargers.
motor.
NOTE: Refer to paragraph 4-2. for troubleshooting of
10-5.DRIVE MOTORS. battery charger 004978 used of trucks Serial
Number 344163 To 376499
Refer to Figure 12-8 and Figure 12-9 for motor disas-
sembly.
Table 10-1 Battery Chargers
CHARGER VOLTAGE TYPE EXPLODED SCHEMATIC SERIAL NUMBER EFFECTIVITY.
PART NO. VIEW
004978 120 Smart Figure 12-37 Figure 10-7 344163 TO 376499
004987 120 Smart Figure 12-38 — 344163 TO 376499
004976-01 * 120 Smart Figure 12-40 Figure 10-6 333375 TO 344162
004967-01 ** 120 Timer Figure 12-41 Figure 10-5 333375 TO 344162
004980 240 Smart Figure 12-37 — 344163 TO 376499
004967-02 240 Timer Figure 12-41 Figure 10-5 333375 TO 344162
* Optional Charger
** Standard Charger

R3024

Figure 10-5 Battery Charger 004967-01 and 004967-02 Schematic

10-6 PDI0404
 R5280

Figure 10-6 Battery Charger 004976-01 Schematic

120 V AC MALE OUTLET

PLUG FLANGED AMMETER
GR

CHARGER
CONNECTOR
15A
FUSE

CIRCUIT
BREAKER

INDICATOR LOGIC BRD

SINK L HEAT SINK

LOGIC
BOARD
TRANSF

(120 VAC) AUTOMATIC CHARGER

R5962

Figure 10-7 Battery Charger 004978 Schematic

PDI0404 10-7
10-7.BATTERIES. a. Truck Serial Number 334289 to 342391,
remove two nuts (22), two lockwashers (21),
NOTE: Batteries are removed from the right side of two bolts (18) and two handle rods (20).
the truck (see Figure 10-8). When installing a
new battery, be sure handles are securely b. Truck Serial Number 333375 to 334288,
fastened to battery, battery cables are remove four screws (25) and four lockwash-
securely attached to battery terminals, and ers (24) securing two battery handles (19) to
cables are routed and secured to the battery two handle rods (23).
as shown in Figure 10-8. 6. Trucks Serial Number 333375 to 342391, install
the two battery handles and two handle rods on
CAUTION: Failure to properly route and wrap bat-
the new battery.
tery cables can damage cables and
make battery installation difficult. 7. Install two cable connectors (8 and 17) on termi-
nals of new battery, and slide battery back into
1. Turn key to off, and remove from key switch. compartment, being careful not to damage
cables.
NOTE: Batteries are heavy. Use care when sliding
out of battery compartment. 8. Trucks Serial Number 347282 To 376499, rein-
stall and position retainer bar (30) to prevent bat-
2. Truck Serial Number 342392 To 376499, remove tery movement in excess of 1/2".
screw (32), washer (31) and retainer bar (30).
3. Remove batteries from the right side of the truck. 10-8.FUSE.
The battery connecting cables are sufficiently 1. Remove two screws (1, Figure 10-8), two lock-
long to allow batteries to be placed on the floor. washers (2), and four brass washers (3) securing
4. Disconnect cable connectors (8 and 17) from bat- the two cables (9, 12), fuse (4), and two standoff
tery terminals. insulators (5).
5. Trucks Serial Number 333375 to 342391, 2. Install two standoff insulators (5), new fuse (4)
remove battery handles as follows: and two cables (9, 12), four brass washers (3)
(two behind fuse and two in front of two cables),
two lockwashers (2), and two screws (1).

10-8 PDI0404
 R5809

Figure 10-8 Base, Frame and Electrical Components

PDI0404 10-9
10-9.HIGH SPEED LIMIT SWITCH. 3. Position bracket with new switch in place on
frame, and secure with washer (2), lockwasher
1. Disconnect wiring from high speed limit switch (5,
(3), and nut (4).
Figure 10-9), then remove nut (4), lockwasher (3),
and washer (2) securing switch mounting bracket 4. Reconnect wiring to switch.
(1) to frame.
2. Remove high speed limit switch from bracket, and 10-10.HORN.
install new switch onto bracket. 1. Disconnect wiring from horn (19, Figure 10-9),
then remove nut (4), lockwasher (3) and washer
NOTE: Bracket must be positioned so that switch is (2) securing horn.
operated when lift carriage is down.
2. Remove horn.
3. Position new horn in place, reinstall nut, lock-
washer and flat washer, then reconnect wiring.

R5810

Figure 10-9 Electrical Components

10-10 PDI0404
 SECTION 11
OPTIONAL EQUIPMENT

11-1.KEYSWITCH Numbers in parenthesis are parts list item number for

Those trucks which have a keyswitch installed will Figure 12-46.
have the wiring modified. The modification is shown in 11-5.1.PUSHBUTTON BOX REMOTE CONTROL
Figure 12-42 and the schematic diagram Figure 4-6 or
Figure 4-7. 1. Add solenoid to pump.
2. Connect a piece of wire (1, Figure 12-46, Frame
11-2.HOUR METER A) from lowering solenoid (2) to negative side of
The hour meter is attached to the motor circuits to indi- pump motor.
cate actual usage of the drive and lift function. Refer to 3. Connect wire 8 from pump motor solenoid to ter-
Figure 12-43 for replacement parts and to the sche- minal 3 on connector (3).
matic diagram, Figure 4-6 or Figure 4-7, for wiring 4. Connect wire 9 from remaining terminal on lower-
information. ing solenoid (2) to terminal 2 on remote connector
(3).
11-3.BATTERY CAPACITY INDICATOR.
5. Connect wire from remote connector (14) terminal
Refer to Figure 12-44 and Figure 12-45 for the battery 1 to deadman switch terminal 3.
capacity indicator replacement parts. Figure 12-44
and Figure 12-45 include both the indicator with and 11-5.2.CONTROL HEAD LIFT/LOWER
without the lift lockout feature.
1. Add solenoid to pump.
11-4.REMOTE CONTROL. 2. Connect a piece of wire (1, Figure 12-46, Frame
B) from lowering solenoid (2) to negative side of
Figure 12-46 identifies the part required for the pump motor.
optional lift and lower remote control. Included are wir-
ing details for both the control head pushbutton 3. Connect wire 8 from pump motor solenoid to ter-
switches and the umbilical connected control box. minal 11 of connector on panel.
4. Connect wire 9 from lowering solenoid (2) to ter-
11-5.REMOTE CONTROL INSTALLATION minal 13 of connector on panel.
Refer to wiring diagrams shown in Figure 12-46 for ref- 5. Connect a jumper between terminals 10 and 11
erence. Refer to subparagraph 11-5.1. for installation on back side connector on panel.
of pushbutton box remote control. Refer to subpara- 6. Connect a jumper between terminals 12 and 13
graph 11-5.2. for lift/lower controls in the control head. on back side of connector on panel.

PDI0404 11-1
 NOTES

11-2 PDI0404
 SECTION 12
ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the PDI Lift Truck.

PDI0404 12-1
 SEE Figure 12-2 1. SEE SUPPLEMENT 207 FOR
FOR SWITCHES TRANSISTOR CONTROL HEAD
USED ON TRUCKS SERIAL
SEE Figure 12-3
NUMBER 333375 TO 334630
FOR COLD CONDITIONING
2. SEE SUPPLEMENT 220 FOR
TRANSISTOR CONTROL HEAD
USED ON TRUCKS SERIAL
NUMBER 33463 TO 376499

R3837

Figure 12-1 Control Head Assembly

12-2 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.

— 505050-04 CONTROL HEAD STANDARD 19 070486 ROUND HD. SLOTTED 2

MACHINE SCREW
— 505050-05 CONTROL HEAD REMOTE LIFT 1
20 072400-01 HEX HD. SLOTTED SCREW, 4
IN HANDLE
6-32 X 1/2
— 505050-06 CONTROL HEAD REMOTE LIFT 1
21 072415 PAN HD. SCREW, 1
LOWER IN HANDLE
THREAD CUTTING
1 005647 CONNECTOR 1
22 073461 SOCKET SET SCREW 2
2 018202 SWITCH INSULATOR 1
23 074711 SPACER 1
3 020669 MICRO SWITCH 1
24 075088 RETURN SPRING 1
4 020775 MICRO SWITCH 4
25 075510 COMPRESSION SPRING 2
5 052956 FLANGED BEARING 2
26 077007 WASHER 4
6 056617 FORWARD-REVERSE DECAL 1
27 077204 SPLIT LOCK WASHER #6 4
7 059633 HEX LOCKNUT, 2-56 2
28 402827 SHAFT 1
8 059634 HEX LOCKNUT, 4-40 2
29 402828 CAP 2
9 060579 DOWEL PIN, 1/4 X 15/16 2
30 402830 BOTTOM ACCESS COVER 1
10 060942 ROLL PIN, 1/8 X 1-1/4 2
31 403358 TUBE 2
11 061016 ROLL PIN, 1/4 X 3 2
32 402836 SPACER 2
12 061200-01 SPIROL PIN, 3/16 X 1 1
33 402837 BRACKET 1
13 067416 PAN HD. SCREW, 6-32 X 1/2 4
34 402839 TUBE 1
14 068189 RD. HD. SCREW, 4-40 X 1-7/8 2
35 402840 CAM 1
15 069462 SLOTTED FLAT HD. SCREW, 2
36 402841 HANDLE GUARD 1
6-32 X 3/4
37 402843 PAD 2
16 069463 SLOTTED FLAT HD. SCREW, 2
6-32 X 1 38 504538-01 SWITCH WIRE ASSEMBLY 3
17 069478 PHILLIPS FLAT HD. SCREW, 4 39 505052 SWITCH BRACKET 1
1/4-20 X 3/4 40 800272 CONTROL LEVER 2
18 069715 SOCKET FLAT HD. SCREW, 2 41 800273 CONTROL HANDLE 1
1/4-20 X 3/4 42 800274 COVER 1

PDI0404 12-3
 R3838

Figure 12-2 Push Button Switches, Control Head

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 005643 CONTACT PIN 2 MAX. 10 056619-01 HORN DECAL 1
2 005649 CONNECTOR 1 11 056619-03 LIFT DECAL 1
3 020697 PUSHBUTTON SWITCH 2 MAX. 12 056619-04 LOWER DECAL 1
4 020698 PUSHBUTTON SWITCH 1 13 067415 PAN HD. SCREW 6-32 X 1/4 A/R
5 021208 TERMINAL 4 MAX. 14 067416 PAN HD. SCREW 6-32 X 1/2 4
6 023014 WIRE A/R 15 402830 TOP COVER 1
7 023170 WIRE HARNESS ASSEMBLY 1 16 402831 TOP COVER 1
8 053215-02 HOLE PLUG 1 17 402832 TOP COVER 1
9 053215-03 HOLE PLUG 1 18 402842 SWITCH PLATE 1

A/R - AS REQUIRED

12-4 PDI0404
 R3966

Figure 12-3 Cold Conditioning, Control Head

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 018909 RESISTORS 2 8 077204 LOCKWASHER 2
2 068186 SCREW 2 9 072400-01 SCREW 2
3 023014 WIRE A/R 10 059632 NUT, HEX, 5-40 2
4 400544 BRACKET, RESISTOR 1 11 400044 BRACKET THERMAL CUTOUT 1
5 018214 INSULATOR, SWITCH 1 12 020736 THERMAL CUTOUT SWITCH 1
6 402829 BRACKET 1 13 005643 CONTACT PIN 2
7 077007 WASHER, FLAT 2
A/R - AS REQUIRED

PDI0404 12-5
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 345826
345828 TO 345865
345871 TO 345389

HANDLE RETURN SPRING KIT

PART NUMBER 901325
CONTAINS:
ITEM QTY
1 1
2 1
10 10

R5806

Figure 12-4 Steering Arm and Electrical Cable

12-6 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505765-02* CONTROL ARM ASSY 1 18 060300 . CLEVIS PIN 1
1 075060** . SPRING, RETURN 1 19 056200 . CLEVIS 1
2 501371** . SPRING TUBE 1 20 063478 . SCREW, HEX CAP, 1/4-20 X 3/4 1
3 402455* . PIVOT CAP 1 21 504364 . CLAMP ASSY 1
3 800064*** . PIVOT CAP 1 22 069478 SCREW, FLAT HD, 1/4-20 X 3/4 1
4 052876 . BUMPER 2 23 023129 CONTROL CABLE 1
5 071377 . SCREW, PAN HD, 10-32 X 3/4 3 — 005640 . SCREW TYPE CONNECTOR 1
6 285302** . SPRING PIN 1 — 005642 . SOCKETS FOR P/N 055640 12
7 285303** . SPRING PIN 1 — 005452 . SQUARE SOCKET PLUG 1
8 077210** . WASHER, LOCK, SPLIT, 5/16 2 — 005626 . PINS FOR P/N 005452
9 059426** . NUT, HEX 5/16-18 2 24 065481 SCREW, SOCKET HD, 1/4-20 X 1 4
10 800204 . TUBE CLAMP 1 25 402459* PIVOT CAP COVER 1
11 052922 . FLANGED BEARING 1 25 191045*** PIVOT CAP COVER 1
12 800275 . STEERING ARM 1 26 065603*** SCREW, SOCKET HD, 2
3/8-16 X 3/4
13 065569 . SCREW, SOCKET HD, 1
7/16-14 X 2-1/4 27 504364 CABLE CLAMP AND 2
NUT ASSEMBLY
14 401127 . SPACER 1
28 061050** ROLL PIN, 3/8 X 1-1/4 1
15 052925 . FLANGED BUSHING 1
29 061006** ROLL PIN, 1/4 X 1-1/4 1
16 501396 . BRAKE ROD 1
30 061716* SNAP RING 2
17 060417 . COTTER PIN, 3/32 X 3/4 2
31 402452* PIN 1
* USED ON TRUCKS SERIAL NUMBER 345827, 345866 TO
345870, 345390 TO 376499
** HANDLE RETURN SPRING KIT PART NUMBER 901325
*** USED ON TRUCKS SERIAL NUMBER 333375 TO 345826,
345828 TO 345865, 345871 TO 345389

PDI0404 12-7
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 339404

R5807

Figure 12-5 Pivot Tube Assembly

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 053108 BUSHING 2 10 505683-01*** PIVOT TUBE WELDMENT (SEE 1
NOTE 1)
2 061000 ROLL PIN 2
10 504574** PIVOT TUBE WELDMENT (SEE 1
3 401695 SPACER 1
NOTE 2)
4 051146 BEARING 1
11 069710 SCREW 4
5 060417 COTTER PIN 1
12 283902* LOWER SPACER 1
6 800005 PIN 1
13 283906 LOWER COLLAR 1
7 283902 SPACER 1
14 073492 SETSCREW 1
8 077211* WASHER, LOCK, SPLIT, 3/8 1
9 065605* SCREW, SOCKET HD, 3/8-16 X 1 1
NOTE 1:TOOL KIT PART NUMBER 907151 REQUIRED FOR * USED ON TRUCKS SERIAL NUMBER 333375 TO 339404
REMOVAL AND INSTALLATION OF PIVOT TUBE ** USED ON TRUCKS SERIAL NUMBER 333375 TO 345826,
WELDMENT PART NUMBER 505683-01. 345828 TO 345865, 345871 TO 345389.
NOTE 2:ORDER PIVOT TUBE KIT PART NUMBER 903275. *** USED ON TRUCKS SERIAL NUMBER 345827, 345866 TO
345870, 345390 TO 376499.

12-8 PDI0404
 NOTES

PDI0404 12-9
 R6110

Figure 12-6 Brake and Linkage

12-10 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 053109 LOCK BUSHING 2 17 800188 LINK PIN 1
2 060417 COTTER PIN, 3/32 X 3/4 5 18 052821 DISC BRAKE PAD ASSEMBLY 1
3 053106 FLANGED BUSHING 1 19 059421 . NUT 2
4 111104 UPPER PIVOT PLATE 1 20 901189 . BOLT 2
5 060320 CLEVIS PIN 1 21 901190 . SPACER 2
6 060321 CLEVIS PIN 1 22 901191 . SPRING 2
7 504573 BRAKE ROD WELDMENT 1 23 901188 . BRAKE PAD 1
8 503523 BRACKET 1 24 901198 . C-RING 1
9 077209 LOCK WASHER, SPLIT, 1/4 5 25 901197 . WASHER 1
10 063482 SCREW 2 26 901196 . SPRING 1
11 403182 MOUNTING BLOCK 2 27 901192 . BRAKE PAD WITH PIN 1
12 063477 SCREW, CAP, HEX HD, 3 28 901195 . BRAKE 1
1/4-20 X 5/8 29 901194 . LEVER 1
13 400804 PIN 1 30 901193 . WASHER 1
14 077011* WASHER, FLAT, 5/16 1 31 077209 . LOCK WASHER, SPLIT, 1/4 2
15 505232 BRAKE LEVER 1 32 505256 DISC ASSEMBLY 1
16 403179 ROD 1 33 403378* SPACER 1
* SPACER, ITEM 33, USED IN PLACE OF TWO WASHERS,
ITEM 14.

PDI0404 12-11
 R3851

Figure 12-7 Transmission

12-12 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — DRIVE MOTOR (FIGURE 12-8) REF 27 057256 . GEAR AND SHAFT 1
2 063557 BOLT, 5/16-18 X 1-1/4 4 28 057241 . GEAR 1
3 077210 WASHER, SPLIT, 5/16 4 29 053031 . THRUST BEARING 1
4 403181 MOTOR PLATE 1 30 051204 . BEARING 1
5 065453 SCREW, CAP SOC HD, 10-32 X 1 3 31 051203 . BEARING 2
6 057906 KEY 1 32 051207 . BEARING-NEEDLE THRUST 2
7 — DISC ASSY REF 33 050711 . SHAFT 1
8 051200 BEARING 1 34 051217 . THRUST BEARING 4
9 042132 O-RING, 1.3-IN. DIA. 1 35 053028 . THRUST BEARING 2
10 400683 MOTOR BEARING HOUSING 1 36 073516 . SEAL 1
11 042131 O-RING, 1.6-IN. DIA. 1 37 051215 . BEARING 2
12 073517 SEAL 1 38 074707 . SPACER 1
13 060609 PIN 2 39 057908 . KEY 1
14 077208 LOCK WASHER, 3/16 3 40 057242 . GEAR 1
15 063495 HEX HD SCREW, 1/4-20 X 1/2 2 41 061731 . SNAP RING, EXT, 1-3/8 1
16 — PIVOT TUBE AND PLATE ASSY REF 42 036115 . GASKET 1
(Figure 12-5) 43 800184 . COVER 1
17 502674 WHEEL AND HUB ASSY 1 44 060609 . PIN 2
18 052764 BOLT 5 45 063482 . SCREW, 1/4-20 X 1-1/4 14
— 901362 TRANSMISSION ASSEMBLY 1 46 077209 . LOCK WASHER, 1/4 14
19 026302 . PLUG, DRAIN 1 47 026310 . PLUG, FILL LEVEL 1
20 051206 . BEARING-NEEDLE THRUST 2 48 076702 . VENT, TRANSMISSION 1
21 051202 . BEARING 2 49 800176 . TRANSMISSION HOUSING 1
22 306808 . SPACER 1 50 057238 . GEAR 1
23 057240 . GEAR 2 51 057909 . KEY 3
24 057258 . GEAR AND SHAFT 1 52 057257 . GEAR AND SHAFT 1
25 051216 . BEARING 1 53 057237 . GEAR 3
26 051208 . BEARING-NEEDLE THRUST 1 54 060974 . ROLL PIN 1

PDI0404 12-13
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 371793

R646

Figure 12-8 Drive Motor 016046

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016046* DRIVE MOTOR 1 7 901268 . TERMINAL KIT 1
1 901264 . FIELD COIL SET 1 8 — . LOCK WASHER, 1/4 4
2 901265 . ARMATURE 1 9 — . FILLISTER HD SCREW, 4
10-33 X 3/4
3 901266 . COMMUTATOR END BEARING 1
10 901269 . BRUSH HOLDER 1
4 900450 . BRUSH SET 1
5 900451 . BRUSH SPRING SET 1
11 — . POLE SHOE SCREW 2
3/8-16 X 1/2 FL. HD
6 901267 . COMMUTATOR END HD 1

* FOR REPLACEMENT OF COMPLETE DRIVE MOTOR

ASSEMBLY 016046 ORDER DRIVE MOTOR 016052.

12-14 PDI0404
 USED ON TRUCKS
SERIAL NUMBERS
371794 TO 376499

R6109

Figure 12-9 Drive Motor 016052

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016052 DRIVE MOTOR ASSY 1 5 900451 . FIELD RING 1
1 907176 . ARMATURE 1 6 901267 . BRUSH SET 1
2 901265 . BEARING, COMMUTATOR END 1 7 901268 . SPRING SET 1
3 901266 . FIELD COILS 1 8 901179 . BRUSH HOLDER 1
4 900450 . POLE SHOES 1 9 907180 . HEAD, COMMUTATOR 1

PDI0404 12-15
 R5808

Figure 12-10 Base and Frame

12-16 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — BASE AND FRAME 1 10 402236 SPACER 1
2 504579 SCREEN 1 11 025713 GREASE FITTING 2
3 077030 WASHER, FLAT NO. 10 4 12 504570 COVER 1
4 077209 WASHER, SPLIT, LOCK, 1/4 9 13 060106 SOUNDPROOF PAD 1
5 059421 NUT, HEX, 1/4-20 4 14 077031 WASHER, FLAT 2
6 057511 GROMMET 1 15 077207 WASHER EXT TOOTH NO. 10 3
7 070476 SCREW, RD HD, 1/4-20 X 1/2 9 16 059416 NUT, HEX, 10-32 3
8 402261 COVER 1 17 402258 CHANNEL 1
9 068190 SCREW, RD HD, 4-40 X 3/8 2

PDI0404 12-17
 R5818

Figure 12-11 Decal Location

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 056478 LIFT-LOWER DECAL 1 8 056625 WARNING DECAL 1
2 056499 NO RIDING DECAL 1 9 056626 OIL LEVEL 1
3 056564 CAUTION DECAL 2 10 056595 CASTING LOGO 1
4 056494 CAUTION DECAL 2 11 056596-08 INSERT PDI 1
5 056632 SMALL MAST DECAL 2 12 056646 INSTR-CHARGER 1
6 056610 WARNING DECAL 1 13 056648 DANGER-BATTERY 1
7 056644 TRUCK-CHARGE DECAL 1
DECAL KIT PART NUMBER 905001 CONSISTS OF ITEMS 1-9

12-18 PDI0404
 R3828

Figure 12-12 Adjustable Straddle Frame

INDEX PART NO.

NO. NO. PART NAME REQD.
1 504696-01* RIGHT HAND STRADDLE 1
1 505347-01** RIGHT HAND STRADDLE 1
(PDI 2024)
1 505347-02** RIGHT HAND STRADDLE 1 LOAD WHEEL AND AXLE KIT
(PDI 2018) PART NUMBER 901326
1 505788-01*** RIGHT HAND STRADDLE 1 CONTAINS:
(PDI 2024)
ITEM QTY
1 505788-02*** RIGHT HAND STRADDLE 1 1 2
(PDI 2018)
2 2
2 504697-01* LEFT HAND STRADDLE 1 3 2
2 505348-01** LEFT HAND STRADDLE 1 7 1
(PDI 2024) R1756
8 1
2 505348-02** LEFT HAND STRADDLE 1
(PDI 2018) Figure 12-13 Load Wheels
2 505789-01*** LEFT HAND STRADDLE 1
INDEX PART NO.
(PDI 2024)
NO. NO. PART NAME REQD.
2 505789-02*** LEFT HAND STRADDLE 1
— — WHEEL AND AXLE ASSY 2
(PDI 2018)
1 061725* . SNAP RING 2
3 077217 WASHER 4
2 077033* . SPACER WASHER 2
4 063869 HEX HEAD BOLTS 4
3 270306* . AXLE 1
4 063870*** HEX HEAD BOLTS 4
— 078409* . LOAD WHEEL ASSY (STD) 1
* USED ON TRUCKS SERIAL NUMBER 333375 TO 338205
(4 IN. DIAMETER)
** USED ON TRUCKS SERIAL NUMBER 338206 TO 353701
4 — . . LOAD WHEEL, POLY 1
*** USED ON TRUCKS SERIAL NUMBER 353702 TO 376499
5 051128 . . ROLLER BEARING 1
— 078256 . LOAD WHEEL ASSY.
(OPTIONAL)
(3 IN. DIAMETER)
6 077038 . RETAINING WASHER 2
7 025713* . GREASE FITTING 1
8 060974* . PIN, ROLL 1
* INCLUDED IN LOAD WHEEL AND AXLE KIT PART NUM-
BER 901326 (1 KIT PROVIDES FOR 1 LOAD WHEEL)

PDI0404 12-19
 USED ON TRUCKS
SERIAL NUMBERS
338206 TO 376499

R5822

Figure 12-14 Elevation System (Telescopic)

12-20 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 VAR INNER MAST 1 16 060402 COTTER PIN 4
2 — NOT USED 17 402051 ADJUSTING BOLT 2
3 — NOT USED 18 059545 JAM NUT 2
4 — NOT USED 19 077215 WASHER, LOCK 2
5 — NOT USED 20 059445 NUT, HEX 2
6 — NOT USED 21 063603 HEX HD CAP SCREW 1
— 901366 ROLLER ASSEMBLY 2 22 077211 WASHER, LOCK 3
7 062326 . ROLLER 2 23 077076 WASHER, FLAT 1
8 051102 . BEARING 2 24 — LIFT CYLINDER (Figure 12-22) REF
9 053000 SHIM A/R 25 057756 RAM HEAD 1
9 053001 SHIM A/R 26 051120 BEARING 2
9 053002 SHIM A/R 27 074251 SHEAVE 2
9 053003 SHIM A/R 28 077022 WASHER 2
10 074805 SPINDLE 2 29 061727 SNAP RING 2
11 053000 SHIM A/R 30 025712 GREASE FITTING 2
11 053001 SHIM A/R 31 063715 HEX HD CAP SCREW 1
11 053002 SHIM A/R 32 077213 WASHER, LOCK 1
11 053003 SHIM A/R 33 064607 HEX HD CAP SCREW 2
— 901365 ROLLER ASSEMBLY 2 34 — LIFT CARRIAGE (Figure 12-18) REF
12 051102 . BEARING 2 35 — SPINDLE (Figure 12-18) 4
13 062325 . ROLLER 2 36 053000 SHIM A/R
14 402055 CHAIN PIN 4 36 053001 SHIM A/R
15 402034 CHAIN (96 IN. LIFT - 7.7 FT) 2 36 053002 SHIM A/R
(108 IN. LIFT - 8.7 FT) 36 053003 SHIM A/R
(120 IN. LIFT - 9.7 FT) 37 901366 ROLLER ASSEMBLY 6
(132 IN. LIFT - 10.7 FT) — 062326 . ROLLER 6
(144 IN. LIFT - 11.7 FT)
— 051102 . BEARING 6

A/R - AS REQUIRED

PDI0404 12-21
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 338205

R5829

Figure 12-15 Elevation System (Telescopic)

12-22 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 VAR INNER MAST 1 18 059545 JAM NUT 2
2 501297 ROLLER BEARING AND HOUS- 2 19 077215 WASHER, LOCK 2
ING 20 059445 NUT, HEX 2
3 100021 SHIM 2 21 063603 HEX HD CAP SCREW 1
4 245736 SHIM 2 22 077211 WASHER, LOCK 3
5 077410 WASHER, LOCK, 3/8 4 23 077076 WASHER, FLAT 1
6 064605 HEX HD CAP SCREW, 3/8-16 X 1 4 24 — LIFT CYLINDER (Figure 12-22) REF
7 — NOT USED 25 057756 RAM HEAD 1
8 — NOT USED 26 051120 BEARING 2
9 — NOT USED 27 074251 SHEAVE 2
10 074805 SPINDLE 4 28 077022 WASHER 2
11 053000 SHIM A/R 29 061727 SNAP RING 2
11 053001 SHIM A/R 30 025712 GREASE FITTING 2
11 053002 SHIM A/R 31 063715 HEX HD CAP SCREW 1
11 053003 SHIM A/R 32 077213 WASHER, LOCK 1
— 500170 ROLLER ASSEMBLY 8 33 064607 HEX HD CAP SCREW 2
12 051102 . BEARING 8 34 — LIFT CARRIAGE (Figure 12-18) REF
13 062300 . ROLLER 8 35 — SPINDLE (Figure 12-18) 4
14 402055 CHAIN PIN 4 36 053000 SHIM A/R
15 402034 CHAIN (96 IN. LIFT - 7.7 FT) 2 36 053001 SHIM A/R
(108 IN. LIFT - 8.7 FT) 36 053002 SHIM A/R
(120 IN. LIFT - 9.7 FT) 36 053003 SHIM A/R
(132 IN. LIFT - 10.7 FT)
37 500170 ROLLER ASSEMBLY 8
(144 IN. LIFT - 11.7 FT)
— 051102 . BEARING 8
16 060402 COTTER PIN 4
— 062300 . ROLLER 8
17 402051 ADJUSTING BOLT 2

A/R - AS REQUIRED

PDI0404 12-23
 R1752

Figure 12-16 Elevation System (Non-Telescopic)

12-24 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — LIFT CYLINDER (Figure 12-21) REF 17 060402 COTTER PIN 4
2 402034 CHAIN (60 IN. LIFT - 3.86 FT) 2 18 402051 ADJUSTING BOLT 2
(72 IN. LIFT - 4.86 FT) 19 059545 JAM NUT 2
(84 IN. LIFT - 5.86 FT) 20 077215 WASHER, LOCK 2
3 064709 HEX HD CAP SCREW 1 21 059445 NUT, HEX 2
4 077213 WASHER, LOCK 1 — 500170* ROLLER ASSEMBLY 4
5 057756 RAM HEAD 1 22 062300* . ROLLER 4
6 051120 BEARING 2 23 051102* . BEARING 4
7 074251 SHEAVE 2 — 901365** ROLLER ASSEMBLY 4
8 077022 WASHER 2 22 062325** . ROLLER 4
9 061727 SNAP RING 2 23 051102** . BEARING 4
10 025712 GREASE FITTING 2 24 053000 SHIM A/R
11 059429 NUT, HEX 2 24 053001 SHIM A/R
12 077211 WASHER, LOCK 1 24 053002 SHIM A/R
13 101071 CLAMP 1 24 053003 SHIM A/R
14 077076 WASHER, LOCK 1 25 — LIFT CARRIAGE (Figure 12-18) REF
15 063603 HEX HD CAP SCREW 1 26 500512* SPINDLE 4
16 402055 CHAIN PIN 4 26 074805** SPINDLE 4

A/R - AS REQUIRED

* USED ON TRUCKS SERIAL NUMBER 333375 TO 338206

** USED ON TRUCKS SERIAL NUMBER 338206 TO 376499

PDI0404 12-25
 R5830

Figure 12-17 Elevation System (Full Free Lift)

12-26 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 053000 SHIM A/R 13 901365 ROLLER ASSEMBLY 2
1 053001 SHIM A/R — 051102 . BEARING 2
1 053002 SHIM A/R — 062325 . ROLLER 2
1 053003 SHIM A/R 14 061023 ROLL PIN, 5/16 X 3/4 1
2 901366 ROLLER ASSEMBLY 6 15 — LIFT CYLINDER (Figure 12-23) REF
— 062326 . ROLLER 6 16 060402 COTTER PIN 4
— 051102 . BEARING 6 17 402055 CHAIN PIN 4
3 063603* HEX HD CAP SCREW, 2 18 402034 CHAIN (106 IN. LIFT - 7.5 FT) 2
3/8-16 X 3/4 (130 IN. LIFT - 8.5 FT)
3 064605** HEX HD CAP SCREW, 3/8-16 X 1 2 19 061729 SNAP RING 2
4 077211 WASHER, LOCK 2 20 401639 PIN, SHEAVE 2
5 800297** WASHER 1 21 065555 SOCKET HD CAP SCREW 4
6 073460** SCREW, SET, #10-24 X 1/4 1 22 053012 WASHER, THRUST, 3/32 4
7 403339 STOP BLOCK 2 23 051145 BEARING, ROLLER 2
8 077209 WASHER, LOCK, 1/4 4 24 289205 SHEAVE 2
9 063482 SCREW, 1/4-20 X 1-1/4 4 25 025712 GREASE FITTING 6
10 077076 WASHER, FLAT 1 26 800246 YOKE, SHEAVE 2
11 VAR INNER MAST 1 27 402051 ADJUSTING BOLT 2
12 053000 SHIM A/R 28 059545 JAM NUT 2
12 053001 SHIM A/R 29 077215 WASHER, LOCK 2
12 053002 SHIM A/R 30 059445 NUT, HEX 2
12 053003 SHIM A/R 31 — LIFT CARRIAGE (Figure 12-18) REF
A/R - AS REQUIRED

* USED ON TRUCKS SERIAL NUMBER 333375 TO 351329

** USED ON TRUCKS SERIAL NUMBER 351330 TO 376499

PDI0404 12-27
 R1753

Figure 12-18 Lift Carriage and Forks

12-28 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 SEE LIFT CARRIAGE, RIGID FORK, 1 6 296401 SHAFT, 24 IN WIDE CARRIAGE 1
CHART 1 1 INCH RING
1 SEE LIFT CARRIAGE, 1 6 276605 SHAFT, 24 IN WIDE CARRIAGE 1
CHART 2 ADJUSTABLE FORK FOR 1-1/4 INCH RINGS (TELE-
SCOPIC AND
2 SEE FORKS PDI-2018 2
ALL PDI 2018-2024)
CHART 3
6 276611 SHAFT, 36 IN WIDE CARRIAGE 1
2 SEE FORKS PDI-2024 ONLY 2
FOR 1-1/4 INCH RINGS
CHART 4
7 061725 SNAP RING, 24 INCH CARRIAGE 2
3 504605-01 BACK REST (OPTIONAL) 1
SHAFT (USED ON 296401)
4 077213 WASHER, LOCK, SPLIT, 1/2 4
7 061729 SNAP RING, 36 INCH CARRIAGE 2
5 063705 SCREW, HEX CAP, 1/2-13 X 1 4
SHAFT (USED ON 276605)
8 500512* SPINDLE 4
8 074805** SPINDLE 4
* USED ON TRUCKS SERIAL NUMBER 333375 TO 338206
** USED ON TRUCKS SERIAL NUMBER 338206 TO 376499

CHART 1 RIGID LIFT CARRIAGE (26" WIDE)

PDI-2018 PDI-2024
FORK LENGTH 26 30 36 30 36
PART NO. 504590-01 504590-02 504590-03 504628-01 504628-02

CHART 2 ADJUSTABLE FORK LIFT CARRIAGE

PDI-2018 PDI-2024
CARRIAGE WIDTH 24 36 24 36
NON-TEL TEL FFL NON-TEL TEL NON-TEL TEL FFL NON-TEL TEL S/N TEL S/N
333375 338206
TO TO
338205 376499
PART NO. 504589-01 504589-02 504589-09 504589-03 504589-04 504589-05 504589-06 504589-10 504589-07 504589-08 504589-04

CHART 3 PDI-2018 ADJUSTABLE FORKS (3" WIDE)

CARRIAGE WIDTH 24 36
FORK LENGTH 30 36 42 48 30 36 42 48
FORK PART NO. 503612 503613 503614 503615 500763 501413 501882 501883
FOR RIGID FRAME TRUCK (STD.)
FORK PART NO. FOR ADJUSTABLE 504832-01 504832-02 504832-03 504834-04 504834-01 504834-02 504834-03 504834-04
STRADDLE TRUCK (OPTIONAL)
FOR TRUCKS SERIAL NUMBER 338206 to 376499
FORK PART NO. FOR ADJUSTABLE 503612 503613 503614 503615 500763 501413 501882 501883
STRADDLE TRUCK (OPTIONAL) FOR TRUCKS
SERIAL NUMBER 333375 TO 338206

CHART 4 PDI-2024 ADJUSTABLE FORKS (4" WIDE)

FORK LENGTH 30 36 42 48
FORK PART NO. FOR RIGID FRAME TRUCK (STD.) FOR 057122-01 057122-02 057122-03 057122-04
TRUCKS SERIAL NUMBER 333375 TO 376499
FORK PART NO. FOR ADJ. STRADDLE TRUCK (OPT.) 057122-01 057122-02 057122-03 057122-04
FOR TRUCKS SERIAL NUMBER 333375 TO 338206
FORK PART NO. FOR ADJUSTABLE STRADDLE TRUCK 057120-01 057120-02 057120-03 057120-04
(OPTIONAL) SERIAL NUMBER 338206 TO 376499

PDI0404 12-29
 R1750

Figure 12-19 Hydraulic System (Telescopic and Non-Telescopic)

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 504575 RESERVOIR 1 20 035107 FILTER ASSY 1
2 504578 BREATHER & DIPSTICK 1 21 056110 CLAMP 2
3 025501 ELBOW 2 22 290000 TUBING A/R
4 282500 TUBING A/R 23 025113 ADAPTER 1
5 070476 SCREW, HEX 1/4-20 1/2 6 24 025124 ADAPTER 1
6 077209 WASHER, LOCK, 1/4 12 25 025524 ELBOW, 90° 1
7 077031 WASHER, FLAT 4 26 — PUMP & MOTOR (Figure 12-29, REF
Figure 12-30 AND Figure 12-31)
8 402259 BRACKET 1
27 025313 CONNECTOR 1
9 — LIFT CONTROL VALVE ASSY REF
(Figure 12-24 AND 28 047110 VALVE, FLOW CONTROL 1
Figure 12-25) 29 026110 NIPPLE 1
10 026701 ELBOW, 1/4 2 30 026708 ELBOW 1
11 026131 NIPPLE, 1/4 3 31 — LIFT CYLINDER (Figure 12-21 REF
12 056118 CLAMP, NOSE 2 AND Figure 12-22)
13 025134 COUPLING, 3/8 PIPE TO 1/4 1 32 065476 SCREW, HEX 1/4-20 1/2 4
SWIVEL 33 064605 SCREW HEX CAP, 3/8-16 2
14 026500 REDUCER 4 34 077211 WASHER, LOCK, SPLIT, 3/8 2
15 027107 TEE 1 35 025538 ELBOW, 90°, 3/8 1
16 025303 ELBOW, 45° SWIVEL 1 36 048133 SOLENOID VALVE, LOWERING 1
17 504591-01 HOSE ASSY 1 (OPTIONAL)
18 504592-01 HOSE ASSY 1 37 077011 WASHER, FLAT 2
19 026302 PLUG, MAGNETIC 1 A/R - AS REQUIRED

12-30 PDI0404
 R5821

Figure 12-20 Hydraulic System (Full Free Lift)

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 077209 WASHER, LOCK, 1/4 10 22 035106 FILTER ASSEMBLY 1
2 505433 RESERVOIR 1 23 056110 CLAMP 2
3 070476 SCREW, HEX 1/4-20 1/2 6 24 290000 TUBING A/R
4 077031 WASHER, FLAT 4 25 025113 ADAPTER 1
5 077211 WASHER, LOCK, SPLIT, 3/8 2 26 025536 ELBOW 1
6 026917 FITTING, HOSE, 3/8 JIC SWVL 2 27 — PUMP & MOTOR (Figure 12-29, REF
Figure 12-30 AND Figure 12-31)
7 505097 BREATHER & DIPSTICK 1
28 064605 SCREW HEX CAP, 3/8-16 2
9 025516 ELBOW 1
29 077011 WASHER, FLAT 2
10 402259 BRACKET 1
30 504199-13 HOSE ASSY 1
11 — LIFT CONTROL VALVE ASSY (Fig- REF
ure 12-24 AND 31 047123 FLOW CONTROL VALVE 1
Figure 12-25) 33 026912 CONNECTOR 1
12 026701 ELBOW, 1/4 2 34 065476 SCREW, HEX 1/4-20 1/2 4
13 026131 NIPPLE, 1/4 3 35 025538 ELBOW, 90°, 3/8 1
14 056118 CLAMP, NOSE 2 36 026711 ELBOW, 45°, 3/8 1
15 290000 TUBING A/R 38 026322 NIPPLE 1
16 026500 REDUCER 1 39 025525 ELBOW, 90°, 3/8 1
17 027107 TEE 1 40 025544 ELBOW, 45°, 3/8 1
18 025116 ELBOW 1 41 502474 CLAMP AND NUT ASSEMBLY 1
19 282900 TUBING A/R 42 069477 SCREW, PH, FL HD, 1/4-20 X 1/2 1
20 504592-01 HOSE ASSY 1
21 026302 PLUG, MAGNETIC 1 A/R - AS REQUIRED

PDI0404 12-31
 RETROFIT KIT PACKING KIT
PART NUMBER PART NUMBER
907124 CONTAINS: 907123 CONTAINS:
ITEM QTY ITEM QTY
2 1 2 1
4 1 4 1
7 1 7 1
11 1 11 1
14 1 15 1
15 1

USED ON TRUCKS
SERIAL NUMBERS
333375 TO 338205
R6107

R6106

Figure 12-21 Lift Cylinder (Non-Telescopic)

12-32 PDI0404
 LIFTING HEIGHT (INCHES) 60 72 84
INDEX NO. PART NAME PART NO. PART NO. PART NO. QTY

— HYD. LIFT CYLINDER ASSY 500773 500774 500775 1

1 . TUBE — — — 1
2* . WIPER RING 049508 049508 409508 1
3 . GLAND NUT 800023 800023 800023 1
4* . TOP O-RING 042122 042122 042122 1
5 . RAM — — — 1
6 . RAM STOP 296001 296001 296001 1
7* . BOTTOM O-RING 042105 042105 042105 1
8** . PISTON 045101 045101 045101 1
9* . PACKING ASSY 043106 043106 043106 1
10 . FLAT WASHER 077004 077004 077004 1
11 . JAM NUT, 3/4-16 800293 800293 800293 1
12 . ROLL PIN, 5/16 X 3/4 LG. 061023 061023 061023 1
13 . WASHER 077093 077093 077093 1
14 . PISTON 403863 403863 403863 1
15 . PSP SEAL 042205-01 042205-01 042205-01 1
* 907123 PACKING KIT INCLUDES ITEMS 2, 4, 7, 11 AND 15.
907124 RETROFIT KIT INCLUDES ITEMS 2 , 4, 7, 11, 14 AND 15.

** CYLINDERS EQUIPPED WITH PISTON, ITEM 8, ORDER RETROFIT KIT 907124.

PDI0404 12-33
 PACKING KIT
USED ON TRUCKS PART NUMBER
SERIAL NUMBERS 907138 CONTAINS:
333375 TO 353212
ITEM QTY
2 1
4 1
7 1
11 1
15 1

RETROFIT KIT
PART NUMBER
907139 CONTAINS:
ITEM QTY
2 1
4 1
7 1
11 1
14 1
15 1

R5812

Figure 12-22 Lift Cylinder (Telescopic)

12-34 PDI0404
 LIFT HEIGHT (INCHES) 96 108 120 132 144 QTY
INDEX PART NAME PART NO. PART NO. PART NO. PART NO. PART NO.
NO.
— HYD. LIFT CYLINDER ASSY 503600 503601 503602 503603 503604 1
1 . TUBE 503605 503606 503607 503608 503609 1
2* . WIPER RING 049508 049508 049508 049508 049508 1
3 . GLAND NUT 800023 800023 800023 800023 800023 1
4* . TOP O-RING 042122 042122 042122 042122 042122 1
5 . RAM 274604 274605 274606 274607 274608 1
6 . RAM STOP 400860 400860 400860 400860 400860 1
7* . BOTTOM O-RING 042105 042105 042105 042105 042105 1
8** . PISTON 045101 045101 045101 045101 045101 1
9** . PACKING ASSY 043106 043106 043106 043106 043106 1
10** . FLAT WASHER 077004 077004 077004 077004 077004 1
11* . JAM NUT, 3/4-16 800293 800293 800293 800293 800293 1
12 . ROLL PIN, 5/16 X 3/4 LG. 061023 061023 061023 061023
13** . WASHER 077093 077093 077093 077093 077093 1
14* . PISTON 403717 403717 403717 403717 403717 1
15* . U CUP SEAL 1-1/2 X 2 X 3/8 043130 043130 043130 043130 043130 1

* 907138 PACKING KIT INCLUDES ITEMS 2, 4, 7, 11 AND 15

907139 PACKING KIT INCLUDES ITEMS 2, 4, 7, 11, 14 AND 15

** CYLINDERS EQUIPPED WITH PISTON, ITEM 8, ORDER RETROFIT KIT 907139.

PDI0404 12-35
 PACKING KIT
PART NUMBER
900949 CONTAINS:
ITEM QTY
5 1
6 1
7 1
8 1
10 1
17 2
19 2
21 2
R1583

Figure 12-23 Lift Cylinders (Full Free Lift)

12-36 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 503996-01 FFL CYLINDER ASSEMBLY 1 12 401642 . PISTON, 2.5 DIA. 1
106 IN. LIFT HEIGHT 13 503992-01 . CYLINDER ROD, 106 LIFT HT 1
— 503996-02 FFL CYLINDER ASSEMBLY 1 13 503992-02 . CYLINDER ROD, 130 LIFT HT 1
130 IN. LIFT HEIGHT 14 401641 . WEAR RING 1
1 503995-01 . FFL CYLINDER WELDMENT 1 15 061824 . SNAP RING RETAINER 2
106 IN. LIFT HEIGHT
16 401584 . CYLINDER HEAD, 2.00 DIA. 2
1 503995-02 . FFL CYLINDER WELDMENT 1
17 049517-01* . CYLINDER HD WIPER RING 2
130 IN. LIFT HEIGHT
18 029103 . BREATHER PLUG 2
2 026308 . SQUARE HD PLUG, 1/4 NPT 1
19 043130* . "U" CUP SEAL 2
3 061825 . SNAP RING RETAINER 1
20 401384 . PISTON, 2.00 DIA. 2
4 401645 . CYLINDER HEAD, 2.50 DIA. 1
21 042136* . "O" RING 2
5 042150* . "O" RING 1
22 401646 . WEAR RING 2
6 042151* . BACK-UP RING 1
23 401642-01 . CYLINDER ROD, 106 LIFT HT 2
7 049517-02* . HYDRAULIC CYLINDER 1
23 401642-02 . CYLINDER ROD, 130 LIFT HT 2
WIPER RING
— 055706 LOCTITE 222 ADHESIVE A/R
8 043132* . "U" CUP ROD SEAL 1
— 900893 HYDRAULIC OIL (QUART) AR
9 401652 . CYLINDER BASE, 2.50 DIA 1
— 900855 HYDRAULIC OIL (GALLON) AR
10 042149* . "O" RING 1
11 059128 . FLEXLOC LOCK NUT 3
A/R - AS REQUIRED

* INCLUDED IN PACKING KIT PART NUMBER 900949

SPECIFY TRUCK MODEL NUMBER, LIFT HEIGHT, AND SERIAL

NUMBER WHEN ORDERING LIFT CYLINDER PARTS.

PDI0404 12-37
 BALL CHECK KIT BALL CHECK KIT
PART NUMBER PART NUMBER
900132 CONTAINS: 900132 CONTAINS:
ITEM QTY ITEM QTY
13 1 13 1
14 1 14 1
15 1 15 1

R1755

Figure 12-25 Lift Control Valve

R1809 (Cold Conditioning)
Figure 12-24 Lift Control Valve (Standard) INDEX PART NO.
NO. NO. PART NAME REQD.
INDEX PART NO.
NO. NO. PART NAME REQD. — 503209-02 LIFT CONTROL VALVE ASSY 1

— 504216-07 LIFT CONTROL VALVE ASSY 1 1 240501 . VALVE BODY 1

1 240501 . VALVE BODY 1 2 042104 . O-RING 1

2 042104 . O-RING 1 3 304611 . RELEASE CAM 1

3 304611 . RELEASE CAM 1 4 400045 . SWITCH BRACKET 1

4 052803 . SWITCH BRACKET 1 5 070475 . PHILLIPS ROUND HD SCREW, 1/ 2

4-20 X 3/8
5 070475 . PHILLIPS ROUND HD SCREW, 1/ 2
4-20 X 3/8 6 060937 . ROLL PIN, 1/8 X 5/8 2

6 060937 . ROLL PIN, 1/8 X 5/8 2 7 075015 . HANDLE RETURN SPRING 1

7 075015 . HANDLE RETURN SPRING 1 8 400097 . LIFT CONTROL VALVE CLAMP 1

8 257401 . LIFT CONTROL VALVE CLAMP 1 9 059529 . JAM NUT, 3/8-24 2

9 059529 . JAM NUT, 3/8-24 2 10 057701 . HANDLE 1

10 057702 . HANDLE 1 11 057952 . KNOB 1

11 057952 . KNOB 1 12 020690 . PUMP MOTOR SWITCH/W NUTS 1

12 504594 . PUMP MOTOR SWITCH/W NUTS 1 13* 060608 . PIN, 5/32 X 1-1/4 1

13* 060608 . PIN, 5/32 X 1-1/4 1 14* 051404 . CHECK BALL 1

14* 051404 . CHECK BALL 1 15* 075052 . COMPRESSION SPRING 1

15* 075052 . COMPRESSION SPRING 1 16 026310 . PLUG, 3/8 1

16 026310 . PLUG, 3/8 1 17 400051 . BRACKET 1

* 900132 BALL CHECK KIT, INCLUDES 13, 14, 15 18 065476 . SCREW, SOCKET HD, 1
1/4-20 X 1/2
* 900132 BALL CHECK KIT, INCLUDES 13, 14, 15

12-38 PDI0404
 NOTES

PDI0404 12-39
 R5809

Figure 12-26 Batteries

12-40 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 070488 SCREW, RD HD, 1/4-20 X 3/8 2 17 504609† CONNECTOR AND CABLE ASSY 1
FROM BATTERY TO
2 077209 WASHER, SPLIT, LOCK, 1/4 5
BATTERY
3 077105 WASHER, FLAT BRASS 4
18 063566*** BOLT, 5/16-18 X 5-1/2 2
4 008918 FUSE, 120 AMP 1
19 402262*** HANDLE 4
5 010614 STANDOFF-INSULATOR 1
20 403288*** ROD HANDLE 2
6 056562 DECAL 1
21 077210*** LOCK WASHER 2
7 005450 HANDLE 1
22 059426*** NUT, HEX, 5/16-18 2
8 504608† CONNECTOR AND CABLE ASSY 1
23 402257†† ROD-HANDLE 4
FROM CONNECTOR TO
BATTERIES 24 077210†† WASHER, LOCK, SPLIT, 5/16 4
9 504610 CONNECTOR AND CABLE ASSY 1 25 063553†† SCREW, HEX HD, 5/16-18 X 3/4 4
10 402264 SPACER 1 26 504611-05 CABLE ASSY, MOTOR F1 1
11 063486 SCREW, HEX HD, 1/4-20 X 2-1/4 2 27 504611-01 CABLE ASSY, MOTOR F2 1
12 504611-07 CABLE 6 AWG A/R 28 504611-05 CABLE ASSY, MOTOR A1 1
13 070476 SCREW, RD HD, 1/4-20 X 1/2 1 29 504611-06 CABLE ASSY, MOTOR A2 1
14 077031 WASHER, FLAT 1 30 403614 BATTERY RETAINER BAR 2
15 057508 GROMMET 1 31 077209 LOCKWASHER, 1/4 2
16 003128** BATTERY, 150 A.H. DRY 2 32 063478 SCREW, HEX HD, 1/4-20 X 3/4 2
16 003192* BATTERY, 150 A.H. DRY 2
16 003216 BATTERY, OPTIONAL GEL CELL 2
A/R - AS REQUIRED

† PART NUMBER FOR BOOTS USE ON CABLE ARE AS FOL-

LOWS: 005964-01 RED BOOT 005964-02B BLACK BOOT
†† USED ON TRUCKS SERIAL NUMBER 333375 TO 334289
NOW OBSOLETE. ORDER KIT PART NUMBER 901333
* USED ON TRUCKS SERIAL NUMBER 342392 TO 376499
** USED ON TRUCKS SERIAL NUMBER 333375 TO 342391
*** USED ON TRUCKS SERIAL NUMBER 334289 TO 342391

PDI0404 12-41
 R5695

Figure 12-27 Quick Disconnect Cable Installation

INDEX PART NO.

NO. NO. PART NAME REQD.
— 505632 QUICK DISCONNECT CABLE KIT
1 505630 CONNECTOR ASSEMBLY 4
BATTERY
2 505631 CONNECTOR ASSEMBLY 1
BATTERY
3 505649 CORD ASSY-CHARGING, 1
EXTERNAL

12-42 PDI0404
 NOTES

PDI0404 12-43
 1. SEE SUPPLEMENT 187 FOR
TRANSISTOR CONTROLLER
USED ON TRUCKS SERIAL
NUMBER 333375 TO 338589
2. SEE SUPPLEMENT 233 FOR
TRANSISTOR CONTROLLER
USED ON TRUCKS SERIAL
NUMBER 338590 TO 372811
3. SEE SUPPLEMENT 233 FOR
TRANSISTOR CONTROLLER
USED ON TRUCKS SERIAL
NUMBER 372812 TO 376499

R5810

Figure 12-28 Electrical Components

12-44 PDI0404
INDEX PART NO. INDEX PART NO.
NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 402255 BRACKET 1 11 020729 SWITCH 1
2 077030 WASHER, FLAT NO. 10 4 12 077204 WASHER, LOCK NO. 6 2
3 077207 LOCK WASHER NO. 10 6 13 068179 SCREW, RD, 5-40 X 5/8 3
4 059416 NUT, HEX, 10-32 6 14 018911 RESISTOR 1
5 020673 SWITCH, HIGH SPEED LIMIT 1 15 402256 BRACKET 2
6 — CONTACTOR PANEL REF 16 077007 WASHER, 5/32 I.D. X 5/16 O.D., 3
(Figure 12-33 AND 20 GAUGE
Figure 12-34) 17 077203 WASHER, LOCK, SPLIT, NO. 5 3
7 077211 WASHER, LOCK, SPLIT, 3/8 2 18 059410 NUT, HEX, 5-40 3
8 059429 NUT, HEX, 3/8-16 2 19 009602 HORN 1
9 068238 SCREW, RD HD, 6-32 1-3/4 2 20 059412 NUT, HEX, 6-62 2
10 005405 STRAIN RELIEF 1

PDI0404 12-45
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 341643

R1990

Figure 12-29 Hydraulic Pump and Motor 905046

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016911 PUMP AND MOTOR ASSEMBLY 1 10 905032 . . STUD PACKAGE 1
— 900896-01 . PUMP 1 11 905033 . . PROTECTIVE CAP 1
— 905046 . MOTOR 1 12 905034 . . COMMUTATOR END-SHIELD 1
1 905047 . . 24-VOLT FIELD COIL 1 13 905037 . . RETAINER 1
2 905048 . . ARMATURE 1 14 905038 . . FILLISTER HEAD SCREW 2
3 905049 . . BEARING 1 15 905039 . . FILLISTER HEAD SCREW 2
4 900885 . . DRIVE END HOUSING 1 16 905040 . . SPRING LOCK WASHER 4
5 905041 . . FLAT-HEAD SCREW 4 17 905041 . . FILLISTER HEAD SCREW 4
6 905052 . . RETAINER 1 18 905042 . . BRUSH HOLDER 1
7 905054 . . BEARING 1 19 905043 . . SPIRAL SPRING 2
8 905030 . . SPRING WASHER 1 20 905044 . . CARBON BRUSH SET 1
9 905031 . . RETAINER 1 21 905045 . . PIN 1

12-46 PDI0404
 USED ON TRUCKS
SERIAL NUMBERS
341644 TO 360730
EXCEPT
359732, 359733,
359738, 360545,
360546, 360547,
360549, 360550,
360551, 360572,
360619, 360623,
360633, 360634,
360723, 360727

USED ON TRUCKS SERIAL NUMBERS

341644 TO 353859

R5304
R6180

Figure 12-30 Hydraulic Pump and Motor Assembly 016935

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016935 PUMP AND MOTOR ASSY 1 — 901547 . MOTOR ASSY 1
1 — . SCREW 4 9 — . . DRIVE END HOUSING 1
2 — . LOCK WASHER 4 10 901602 . . BALL BEARING 1
3 900896-01 . PUMP, COMPLETE 1 11 — . . ARMATURE 1
4 036107 . GASKET 1 12 — . . FIELD COIL 1
5 056353 . COUPLING 1 13 901600 . . BRUSH AND HOLDER KIT 1
6 020715 . SOLENOID 1 14 — . . THRUST WASHER PACKAGE 1
7 — . SCREW 2 15 901601 . . COMMUTATOR END HEAD 1
WITH NEEDLE BEARING
8 — . LOCK WASHER 2
16 — . . THRU BOLT 2

PDI0404 12-47
 USED ON TRUCKS SERIAL NUMBERS 367402, 367404, 367406, 367408, 367409, 367410, 367411,
367412, 367413, 367414, 367416, 367417, 367418, 367419, 367432, 367463, 367464, 368852, 368853,
368855, 368878, 368900, 368930, 368931, 368933, 368934, 368935, 368956, 370267, 370281, 370282,
370285, 370292, 370305, 370306, 370307, 370313, 370318, 370358, AND 37036

R6094

Figure 12-31 Hydraulic Pump and Motor Assembly 016942

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016942* PUMP AND MOTOR ASSY REF 2 036107 . GASKET 1
1 901623 . MOTOR ASSY 1 3 056353 . COUPLING 1
— 901624 . . BRUSH ASSEMBLY 1 4 900896-01 . PUMP, COMPLETE 1
* FOR COMPLETE PUMP AND MOTOR ASSY ORDER
016940

12-48 PDI0404
 USED ON TRUCKS SERIAL NUMBERS
359732, 359733, 359738, 360545, 360546, 360547, 360549, 360550, 360551, 360572, 360619,
360623, 360633, 360634, 360723, 360727, 360730 TO 376499
EXCEPT
367402, 367404, 367406, 367408, 367409, 367410, 367411, 367412, 367413, 367414, 367416,
367417, 367418, 367419, 367432, 367463, 367464, 368852, 368853, 368855, 368878, 368900,
368930, 368931, 368933, 368934, 368935, 368956, 370267, 370281, 370282, 370285, 370292,
370305, 370306, 370307, 370313, 370318, 370358, AND 37036

1 3
4

5
OUTPUT
PORT

INLET
PORT

R6025
R6036
016940 PDI CONFIGURATION

Figure 12-32 Hydraulic Pump and Motor Assembly 016940

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 016940 PUMP AND MOTOR ASSY REF 4 906006 . COUPLING 1
1 906003 . SOLENOID 1 5 906007 . MOTOR ASSY 1
2 906004 . PUMP, COMPLETE 1 6 906008 . . BRUSH AND HOLDER KIT 1
3 906005 . GASKET 1

PDI0404 12-49
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 364407

1. SEE SUPPLEMENT 187 FOR

TRANSISTOR CONTROLLER
USED ON TRUCKS SERIAL
NUMBER 333375 TO 338589
2. SEE SUPPLEMENT 233 FOR
TRANSISTOR CONTROLLER
USED ON TRUCKS SERIAL
NUMBER 338590 TO 364407

R3836

Figure 12-33 Electrical Control Panel

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 504662 PANEL ASSEMBLY 1 12 070491 SCREW, RD HD 8-32 X 1 8
1 504660 BASE PLATE 1 13 077205 WASHER LOCK SPLIT 8 8
2 068179 SCREW, RD HD, #5-40 X 5/8 1 14 504611-06 CABLE ASSY-6AWG, 3/8-1/4 RING 2
3 059410 NUT, HEX, #5-40 1 15 504611-05 CABLE ASSY-6AWG, 3/8-1/4 RING 1
4 077203 WASHER, LOCK, SPLIT #5 1 16 504611-01 CABLE ASSY-6AWG, 3/8-1/4 RING 1
5 008904 FUSEHOLDER FOR 008910 1 17 504661 CABLE ASSY 1
(15 AMP FUSE) 18 504611-08 CABLE ASSY 1
6 056504 DECAL, FUSE 15A 1 19 401181 BUSSBAR 3
7 023133 WIRE HARNESS ASSY 1 20 †† CONTACTOR 2ND AND 3RD REF
7A 005627 . CONTACT, AMP 1 SPEED 24V
(Figure 12-35)
7B 005453 . SQUARE CONNECTOR (PART 1
OF 023133 WIRE HARNESS) 21 504611-09 CABLE ASSY 1
8 021712-01 24V 1 SECOND TIME DELAY 1 22 504611-10 CABLE ASSY 1
9 056121 CLAMP, SINGLE 1 23 008910 15 AMP FUSE 1
10 071376 SCREW, TRUSS, #10-32 X 1/2 1 25 021204 TERMINAL-SLIDE CLIP 1/4 1
11 † CONTACTOR FORWARD/ REF 26 077207 WASHER, LOCK, SPLIT #10 1
REVERSE 24V
(Figure 12-36)

NOTE: FOR A COMPLETE SET OF CONTACTOR TIPS FOR ALL CONTACTORS ORDER PART NUMBER 900531-02.
† FOR FORWARD/REVERSE CONTACTOR TIP KIT ORDER PART NUMBER 900531-09. ONE KIT REPAIRS ONE CONTACTOR.
†† FOR SECOND AND THIRD SPEED CONTACTOR TIP KIT ORDER PART NUMBER 900531-08. ONE KIT REPAIRS ONE CONTACTOR.

12-50 PDI0404
 USED ON TRUCKS
SERIAL NUMBERS
364408 TO 376499

1. SEE SUPPLEMENT 233 FOR

TRANSISTOR CONTROLLER
USED ON TRUCKS SERIAL
NUMBER 364408 TO 372811
2. SEE SUPPLEMENT 233 FOR
TRANSISTOR CONTROLLER
USED ON TRUCKS SERIAL
NUMBER 372812 TO 376499

R6083

Figure 12-34 Electrical Control Panel

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 505867 PANEL ASSEMBLY 15 403548 . BUSS BAR 2
1 505869 . BASE PLATE 1 16 403549 . BUSS BAR 2
2 023250 . HARNESS ASSEMBLY 1 17 403828 . BUSS BAR 1
3 008904 . FUSE HOLDER 1 18 077030 . WASHER 7
4 068179 . SCREW, RD HD, #5-40 X 5/8 1 19 504611-18 . CABLE ASSY, 6AWG 1
5 077203 . WASHER, LOCK, SPLIT #5 1 20 504611-04 . CABLE ASSY, 6AWG 1
6 059410 . NUT, HEX, #5-40 1 21 504611-37 . CABLE ASSY, 6AWG, F1 1
7 008910 . 15 AMP FUSE 1 22 504611-24 . CABLE ASSY, 6AWG 1
8 056504 . DECAL, FUSE 15A 1 23 504611-38 . CABLE ASSY, 6AWG, A2 1
9 071376 . SCREW, TRUSS, #10-32 X 1/2 8 24 504611-39 . CABLE ASSY, 6AWG, F2 1
10 077207 . WASHER, LOCK, SPLIT #10 8 25 504611-29 . CABLE ASSY, 6AWG, POS 1
11 021712-01 . 24V 1 SECOND TIME DELAY 1 26 005627 . SQUARE CONNECTOR 1
12 056121 . CLAMP, SINGLE 1 27 021203 . TERMINAL RING, 8-10 STUD 1
13 055668 . SOLENOID-CONTACTOR, 2 28 505872 . CABLE ASSY, HIGH SPEED 1
24V SPEED CUTOUT SWITCH
14 005667 . SOLENOID-CONTACTOR, 2
24V DIRECTIONAL

PDI0404 12-51
 BALL CHECK KIT BALL CHECK KIT
PART NUMBER USED ON TRUCKS PART NUMBER USED ON TRUCKS
900531-08 SERIAL NUMBERS 900531-09 SERIAL NUMBERS
CONTAINS: 333375 TO 364407 CONTAINS: 333375 TO 364407

ITEM QTY ITEM QTY

3 1 3 1
5 1 5 1
8 1 8 1
12 1 12 1
16 1

R1865 R1866

Figure 12-35 Contactor (2nd and 3rd Speed) Figure 12-36 Contactor (Forward/Reverse)

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 005659 CONTACTOR 2ND AND 3RD 1 — 005657 CONTACTOR FORWARD/ 1
SPEED, 100 AMP REVERSE, 100 AMP
1 905010 . BASE MOULDING 1 1 905010 . BASE MOULDING 1
2 905024 . MAGNET FRAME 1 2 905024 . MAGNET FRAME 1
3 905013†† . BRAID ASSEMBLY 1 3 905013† . BRAID ASSEMBLY 1
4 905025 . FRONT MOLDING WITH 1 4 905025 . FRONT MOLDING WITH BLOW- 1
BLOWOUT OUT
5 905015†† . ARMATURE PLATE RETAINER 1 5 905015† . ARMATURE PLATE RETAINER 1
6 905016 . COMPRESSION SPRING 2 6 905016 . COMPRESSION SPRING 2
7 905017 . SPRING STUD 1 7 905017 . SPRING STUD 1
8 905029†† . MOVING CONTACT ASSEMBLY 1 8 905018† . MOVING CONTACT ASSEMBLY 1
9 905019 . ARMATURE PLATE 1 9 905019 . ARMATURE PLATE 1
10 905020 . POLE PIECE 1 10 905020 . POLE PIECE 1
11 905028 . COIL ASSEMBLY, 24 VOLT 1 11 905028 . COIL ASSEMBLY, 24 VOLT 1
12 905022†† . FRONT CONTACT 1 12 905022† . FRONT CONTACT 1
13 905023 . SPACER 1 13 905023 . SPACER 1
14 401181 . BUS BAR (NOT PART OF 1 14 401181 . BUS BAR (NOT PART OF CON- 1
CONTACTOR) TACTOR)
16 905026† . BACK CONTACT 1
17 905027 . REAR MOLDING 1

NOTE: FOR A COMPLETE SET OF CONTACTOR TIPS FOR ALL CONTACTORS ORDER PART NUMBER 900531-02.
† FOR FORWARD/REVERSE CONTACTOR TIP KIT ORDER PART NUMBER 900531-09. ONE KIT REPAIRS ONE CONTACTOR.
†† FOR SECOND AND THIRD SPEED CONTACTOR TIP KIT ORDER PART NUMBER 900531-08. ONE KIT REPAIRS ONE CONTACTOR.

12-52 PDI0404
 USED ON TRUCKS
SERIAL NUMBERS
344163 TO 376499

R5297

Figure 12-37 "Smart" Battery Charger Installation

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 065476 SCREW, HEX HD 1 11 059412 NUT, HEX, 6-32 2
2 077209 WASHER, LOCK, 1/4 split 1 12 057515 GROMMET 1
3 059421 NUT, HEX 1 13 505640 CONNECTOR ASSEMBLY 1
4 008910 FUSE, 15 Amp 1 14 005810 CORD, CHARGER, 120 VAC 1
5 059429 NUT, HEX, 3/8-16 1 14 504599 CORD, CHARGER, 240 VAC 1
6 077211 WASHER, LOCK, 3/8 split 1 15 077064 WASHER, FLAT 2
7 015609 AMMETER 1 16 004978 CHARGER, 120 VAC 1
8 068230 SCREW, MACHINE 2 16 004980 CHARGER, 240 VAC 1
9 005454 CONNECTOR, INLET FLANGE, 1 17 901603 . CIRCUIT BOARD WITH 1
120 VAC HEAT SINK
9 005455 CONNECTOR, INLET FLANGE, 1 18 901604 . CIRCUIT BREAKER 1
240 VAC 19 — . INDICATOR LIGHT 1
10 077204 WASHER, LOCK, SPLIT 2 (PART OF ITEM 16)

PDI0404 12-53
 USED ON TRUCKS
SERIAL NUMBERS
344163 TO 376499

R6118

Figure 12-38 Gel Cell Battery Charger

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 004987 CHARGER KIT-24V, 25 AMP 1 13 505992 BRACKET, CHARGER 1
1 904075 . PCB ASSY WITH HEATSINK 1 14 077209 WASHER-LOCK, SPLIT, 1/4 4
2 904074 . . THERMISTOR 1 15 077421 NUT-HEX, 1/4-20 4
3 003403 . CIRCUIT BREAKER-AUTO 1 16 077064 WASHER, 0.641 X 1.062 X 7 GA 2
RESET 17 059429 NUT-HEX, 3/8-16 1
4 904076 . TRANSFORMER 1 18 026238-26 WIRE ASEMBLY 1
5 077208 WASHER-LOCK, SPLIT, #12 3 19 506178 CONNECTOR ASSY - CHARGER 1
6 059416 NUT-HEX, 10-32 3 20 059412 NUT-HEX, 6-32 2
7 023238-25 WIRE ASSEMBLY 1 21 077204 WASHER - LOCK, SPLIT, #6 2
8 505676-03 WIRE ASSEMBLY 1 22 005461 CONNECTOR - INLET FLANGED 1
9 070476 SCREW-PH RD HD, 1/4-20 X 1/2 4 23 505853 CORD ASSY - EXTENSION, 120 V 1
10 077031 WASHER, 5/16 X 3/4 X 16 GA 5 24 056681 DECAL - CHARGER, LED 1
11 077032 WASHER, 3/16 X 1/2 X 13 GA 1 25 071376 SCREW - PH TR HD, 10-32 X 1/2 2
12 023238-27 WIRE ASEMBLY 1

12-54 PDI0404
 USED ON TRUCKS
SERIAL NUMBERS
333375 TO 344162

R1758

Figure 12-39 Battery Charger Mounting

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 — BATTERY CHARGER (Figure 12- REF 8 005454 CONNECTOR, INLET FLANGE, 1
40 AND Figure 12-41) 120 VAC
2 065476 SCREW, HEX HD, 1/4-20 X 1/2 2 8 005455 CONNECTOR, INLET FLANGE, 1
240 VAC (OPTIONAL)
3 077209 WASHER, LOCK, 1/4 SPLIT 3
9 068231 SCREW, RD HEAD, 6-32 X 1/2 2
4 077031 WASHER, FLAT, 1/4 2
10 005810 CORD, CHARGER, 120 VAC 1
5 059412 NUT, HEX, ZINC AND YELLOW, 2
1 PHASE (OPTIONAL)
6-32
10 504599 CORD, CHARGER, 240 VAC 1
6 077204 WASHER, LOCK, SPLIT, NO. 6 2
50 HZ, 1 PHASE (OPTIONAL)
7 068230 SCREW, HEX HEAD, 1/4-20 X 5/8 1

PDI0404 12-55
 USED ON TRUCKS SEE SUPPLEMENT
SERIAL NUMBERS 304 FOR ADDITIONAL
333375 TO 344162 INFORMATION

R5281

Figure 12-40 Optional "Smart" Charger 004976-01

(Replaces Timer Charger 004967-01)

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 004976-01 "SMART" CHARGER 1 7 907077 . TRIAC (CONTROL CARD) 1
1 901023 . TRANSFORMER 1 8 900847 . FUSE AGC10 1
2 901027 . DIODE/HEAT SINK ASSEMBLY 1 9 901022 . CIRCUIT BREAKER 1
3 900385 . CAPACITOR 1 10 005401 . BATTERY CONNECTOR 1
4 900462 . AMMETER 1 11 900379 . PILOT LIGHT 1
5 907112 . CONTROL CARD 1 12 907058 . FUSE HOLDER 1
(CIRCUIT BOARD)
6 907078 . TRANSFORMER 1
(CONTROL CARD)

12-56 PDI0404
 USED ON TRUCKS SEE SUPPLEMENT
SERIAL NUMBERS 302 FOR ADDITIONAL
333375 TO 344162 INFORMATION

R3025

Figure 12-41 Standard Timer Battery Charger 004967-01 and 004967-02

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
— 004967-01 BATTERY CHARGER, 1 — 004967-02 BATTERY CHARGER, 1
120 V, 60 HZ (STANDARD) 240 V, 50 HZ (OPTIONAL)
1 901023 . TRANSFORMER, 60 HZ 1 1 901024 . TRANSFORMER, 50 HZ 1
2 901027 . RECTIFIER WITH HEAT SINK 1 2 901027 . RECTIFIER WITH HEAT SINK 1
3 900385 . CAPACITOR 1 3 900385 . CAPACITOR 1
4 900462 . AMMETER WITH CLAMP 1 4 900462 . AMMETER WITH CLAMP 1
5 900375 . TIMER, 60 HZ 1 5 900749 . TIMER, 50 HZ 1
6 900376 . TIMER KNOB 1 6 900376 . TIMER KNOB 1
7 900475 . TIMER DIAL PLATE 1 7 900475 . TIMER DIAL PLATE 1
8 901030 . AC FUSE, AGC15 1 8 901030 . AC FUSE, AGC15 1
9 — . NOT USED 9 — . NOT USED
10 005401 . DC PLUG 1 10 005401 . DC PLUG 1
11 900463 . INSULATOR, HEAT SINK 1 11 900463 . INSULATOR, HEAT SINK 1
12 907058 . FUSE HOLDER 1 12 907058 . FUSE HOLDER 1
13 900464 . FUSE 1 13 900464 . FUSE 1
14 901203 . FUSE HOLDER 1 14 901203 . FUSE HOLDER 1

PDI0404 12-57
 SEE
SUPPLEMENT
233 FOR
TRANSISTOR
TRUCKS SERIAL
NUMBER 338590
TO 376499

R1760

Figure 12-42 Optional Keyswitch

INDEX PART NO. R1761

NO. NO. PART NAME REQD.
1 020725 SWITCH, KEY 1 Figure 12-43 Optional Hour Meter
2 021203 TERMINAL, RING NO. 10 2
INDEX PART NO.
3 005627 CONTACT 2
NO. NO. PART NAME REQD.
4 005648 HOUSING, SOCKET, FREE 1
1 015604 HOUR METER 1
HANGING
2 068179 SCREW, RD HD, 5-40 X 5/8 3
5 005626 CONTACT, MALE 2
3 077203 WASHER, LOCK, SPLIT NO. 5 5
6 005647 CONNECTOR 1
4 059410 NUT, HEX, 5-40 5
7 005433 CONNECTOR, IN-LINE 2
5 021718 TERMINAL, SLIP ON, 1/4 2
INSULATED
6 005627 CONTACT 2
7 005648 HOUSING, SOCKET, FREE 1
HANGING
8 005626 CONTACT, MALE 2
9 005647 CONNECTOR 1
10 021207 TERMINAL, RING, 5/16 1
11 021204 TERMINAL, QUICK CONNECT, 2
FEMALE
12 005422 CONNECTOR, IN-LINE 2
INSULATED
13 005992 DIODE ASSEMBLY 1
14 010610 PAD, INSULATING DIODE 1
15 068177 SCREW, RD HD, 5-40 X 3/8 2
16 021203 TERMINAL, RING NO. 10 1

12-58 PDI0404
 OLDER VERSION

R1776

Figure 12-44 Optional Battery Capacitor Indicator

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 010619-02 METER, BATTERY CAPACITY, 1 6 005626 CONTACTS, MALE 2*
24 V W/O LIFT LOCKOUT 7 068177 SCREW, RD HD, 5-40 X 3/8 2
1 010624-02 METER, BATTERY CAPACITY, 1 8 077203 WASHER, LOCK, SPLIT, NO. 5 2
24 V W/LIFT LOCKOUT 9 059410 NUT, HEX 5-40 2
2 021718 TERMINAL, SLIP ON, 1/4 2 OR 7 10 021203 TERMINAL, RING, NO. 10 1
INSULATED
11 005433 CONNECTOR, SPLICE, INLINE 1
3 005648 HOUSING, SOCKET, FREE 1*
12 023014 WIRE, 18 GAUGE, STRANDED A/R
HANGING
13 021207 TERMINAL, RING, 5/16 2
4 005627 CONTACT AMP 2*
5 005647 CONNECTOR 1*
A/R - AS REQUIRED

* DOUBLE QUANTITIES FOR SYSTEM WITH LIFT LOCKOUT

PDI0404 12-59
 NEWER VERSION

R5819

Figure 12-45 Optional Battery Capacitor Indicator

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 010617-02 METER, BATTERY CAPACITY, 1 4 005627 CONTACT AMP 2
24 V W/O LIFT LOCKOUT 5 005647 CONNECTOR 1
1 010618-02 METER, BATTERY CAPACITY, 1 6 005626 CONTACTS, MALE 2
24 V W/LIFT LOCKOUT 7 021204 TERMINAL, FEMALE 2
2 021718 TERMINAL, SLIP ON, 1/4 2 OR 3 8 005422 CONNECTOR, INLINE 1
INSULATED
10 021203 TERMINAL, RING, NO. 10 1
3 005648 HOUSING, SOCKET, FREE 1
12 023014 WIRE, 18 GAUGE, STRANDED A/R
HANGING
13 021207 TERMINAL, RING, 5/16 2

A/R - AS REQUIRED

12-60 PDI0404
 R1777

Figure 12-46 Optional Remote Control Installation

INDEX PART NO. INDEX PART NO.

NO. NO. PART NAME REQD. NO. NO. PART NAME REQD.
1 021203 TERMINAL, RING 8-10 STUD 1 9 077203 WASHER, LOCK, SPLIT, NO. 5 2
2 048133 SOLENOID, 24 V 1 10 059410 NUT, HEX 5-40 2
3 021718 TERMINAL, SLIP ON, 1/4 1 11 017800 PLUG, FEMALE, FLUSH MOUNT 1
INSULATED 12 021236 TERMINAL, RING, NO. 6 4
4 021207 TERMINAL, RING, 5/16 1 13 005648 HOUSING SOCKET, FREE 1
5 023014 WIRE, 18 GAUGE STRANDED A/R HANGING
6 005626 CONTACTS, MALE 1 14 005647 CONNECTOR 1
7 005627 CONTACTS, AMP 4 15 501736 REMOTE ASSEMBLY 1
PUSHBUTTON
8 068177 SCREW, RD HD, 5-40 X 3/8 2
A/R - AS REQUIRED

PDI0404 12-61
 NOTES

12-62 PDI0404
Big Joe Manufacturing Company