Big Joe PDBB-20-T12, Operation, Maintenance, Repair Parts List

Page: 17 / 114

901357 3-1
SECTION 3
PLANNED MAINTENANCE
3-1. GENERAL.
Planned maintenance consists of periodic visual and
operational checks, parts inspection, lubrication, and
scheduled maintenance designed to prevent or dis-
cover malfunctions and defective parts. The operator
performs the checks in
SECTION 2 , and refers any
required servicing to a qualified maintenance techni-
cian who performs the scheduled maintenance and
any required servicing.
3-2. MONTHLY AND QUARTERLY CHECKS.
Table 3-1 is a monthly and quarterly inspection and
service chart based on normal usage of equipment
eight hours per day, five days per week. If the lift truck
is used in excess of forty hours per week, the fre-
quency of inspection and service should be increased
accordingly. These procedures must be performed by
a qualified service technician or your Big Joe service
representative.
3-3. GEL CELL BATTERY CARE.
3-3.1. General.
These Gel Cell Batteries are maintenance-free. Any
attempt to open the battery will void the warranty.
Ultra-deep discharging of brand new batteries
should be avoided for at least 15 cycles.
To dramat-
ically extend battery life, ultra-deep discharge should
be avoided. The shallower the average discharge, the
longer the battery life.
3-3.2. Charging Batteries
Charging requirements will vary depending on depth of
discharge and temperature. Follow safety rules when
placing a battery on charge.
Proceed as follows:
1. Park truck at charging station with platform low-
ered and key switch off.
2. Check the condition of the AC cord, the battery
connector and battery cables. If there are any cuts
in the cable, any exposed wires, loose plugs or
connectors, DO NOT attempt to charge the bat-
teries. Contact appropriate personnel for repairs
to be made.
3. Serial Number 375067 to 380099: Disconnect
the batteries from the truck and connect batteries
to the charger. Make sure connectors are mated
properly.
Serial Number 38100 and Higher: There is no
need to switch the battery connector. An AC
charging relay is used.
4. Connect the AC cord to the truck and then plug
into the 120 VAC power supply.
Table 3-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check drive motor for proper operation
Monthly Check pump motor for proper operation
Monthly Check electrical 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 3-5. )
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 paragraph 8-2. )