Big Joe PDSR 30 Installation, Operation, Maintenance & Repair Parts Download Page 3

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TABLE OF CONTENTS

BL-PDSR 30-0319 - 03-07-2019

Section

Page

Section

Page

1 DESCRIPTION ............................................................1-1

1-1 INTRODUCTION ................................................1-1
1-2 GENERAL DESCRIPTION .................................1-1
1-3 SAFETY FEATURES..........................................1-2

2 OPERATION ...............................................................2-1

2-1 GENERAL...........................................................2-1
2-2 OPERATING PRECAUTIONS............................2-1
2-3 BEFORE OPERATION.......................................2-2
2-4 GENERAL CONTROL OPERATION..................2-4
2-5 DRIVING AND

STOPPING PROCEDURES...............................2-4

2-5.1

STOPPING ................................................2-4

2-6 BELLY-BUTTON SWITCH .................................2-5
2-7 STEERING ARM GAS SPRING ........................2-5
2-8 LIFT AND LOWER CONTROLS........................2-5
2-9 LOADING AND UNLOADING.............................2-5

2-10 PARKING............................................................2-5

3 PLANNED MAINTENANCE ........................................3-1
3-1 GENERAL...........................................................3-1

3-2 MONTHLY AND QUARTERLY CHECKS..........3-1
3-3 BATTERY CARE ................................................3-1
3-3.1

GENERAL..................................................3-1

3-3.2

SAFETY RULES ........................................3-2

3-3.3

BATTERY CARE AND CHARGING...........3-2

3-3.4

BATTERY CLEANING ...............................3-2

3-4  CHARGING BATTERIES ..................................3-3
3-5  LUBRICATION...................................................3-3
3-6  LIFT CHAIN MAINTENANCE ............................3-3

4 TROUBLESHOOTING ................................................4-1

4-1 GENERAL...........................................................4-1
4-2 CONTROLLER TROUBLESHOOTING ..............4-4
4-2.1

ZAPI HANDSET (OPTIONAL) ...................4-4

4-2.2

FAULT DETECTION ..................................4-4

4-2.2.1

GENERAL ............................................4-4

4-2.2.2

LOGBOOK ACCESS............................4-4

4-2.3

TESTING TRUCK OPERATION ................4-4

4-2.4

SETTINGS AND ADJUSTMENTS .............4-5

4-2.4.1

SET OPTIONS .....................................4-5

5 OPERATING CONTROL SYSTEM .............................5-1

5-1 CONTROL HEAD ...............................................5-1
5-1.1

CAP ASSEMBLY REMOVAL.....................5-1

5-1.2

CAP ASSEMBLY INSTALLATION.............5-1

5-1.3

CONTROL HEAD REMOVAL ....................5-1

5-1.4

CONTROL HEAD INSTALLATION ............5-1

5-1.5

POTENTIOMETER REPLACEMENT ........5-1

5.1.6

BELLY-BUTTON
SWITCH REPLACEMENT .........................5-1

5-1.7

HORN SWITCH REPLACEMENT .............5-4

5-1.8

LIFT AND LOWER
SWITCH REPLACEMENT .........................5-4

5-2 COMPARTMENT COVERS ...............................5-4
5-2.1

REMOVAL .................................................5-4

5-2.2

INSTALLATION..........................................5-4

5-3 STEERING ARM................................................ 5-4
5-3.1

RETURN SPRING REPLACEMENT......... 5-4

5-3.2

STEERING ARM REMOVAL..................... 5-4

5-3.3

STEERING ARM INSTALLATION............. 5-4

6 BRAKE SERVICING ................................................... 6-1

6-1 BRAKES............................................................. 6-1
6-1.1

AIR GAP ADJUSTMENT........................... 6-1

6-1.2

STOPPING DISTANCE ADJUSTMENT.... 6-2

6-1.3

BRAKE ASSEMBLY REPLACEMENT...... 6-2

7 DRIVING SYSTEM ..................................................... 7-1

7-1 DRIVE WHEEL .................................................. 7-1
7-2 TRANSMISSION................................................ 7-1
7-3 STEERING MOTOR .......................................... 7-1
7-4 LOAD WHEEL.................................................... 7-1
7-4.1

REMOVAL................................................. 7-1

7-4.2

REPAIR ..................................................... 7-1

7-4.3

LOAD WHEEL INSTALLATION ................ 7-2

8 ELEVATION SYSTEM SERVICING ........................... 8-1

8-1 GENERAL .......................................................... 8-1
8-2 LIFT CHAIN LENGTH ADJUSTMENT............... 8-1
8-3 LIFT CHAIN WEAR INSPECTION..................... 8-2
8-4 LIFT CHAIN REPLACEMENT............................ 8-2
8-4.1

TELESCOPIC............................................ 8-2

8-4.2

TRIMAST FREE LIFT CHAIN.................... 8-4

8-4.3

TRIMAST SECONDARY LIFT CHAIN ...... 8-4

8-5 LIFT CYLINDERS .............................................. 8-4

9 HYDRAULIC SYSTEM SERVICING........................... 9-1

9-1 LINES AND FITTINGS....................................... 9-1
9-2 HYDRAULIC PUMP,

MOTOR AND RESERVOIR ............................... 9-6

9-2.1

REMOVAL................................................. 9-6

9-2.2

DISASSEMBLY AND REASSEMBLY ....... 9-6

9-2.3

INSTALLATION......................................... 9-6

9-2.4

LIFT CYLINDER (TELESCOPIC).............. 9-7

9-2.4.1

REMOVAL ........................................... 9-7

9-2.4.2

REPAIR ............................................... 9-7

9-2.4.3

INSTALLATION ................................... 9-7

9-2.5

LIFT CYLINDER (TRIMAST FREE LIFT).. 9-8

9-2.5.1

REMOVAL ........................................... 9-8

9-2.5.2

REPAIR ............................................... 9-8

9-2.5.3

INSTALLATION ................................... 9-9

9-2.6

LIFT CYLINDER
(TRIMAST SECONDARY)......................... 9-9

9-2.6.1

REMOVAL ........................................... 9-9

9-2.6.2

REPAIR ............................................... 9-9

9-2.6.3

INSTALLATION ................................. 9-10

9-2.7

REACH CYLINDER................................. 9-10

9-2.7.1

REMOVAL ......................................... 9-10

9-2.7.2

REPAIR ............................................. 9-10

9-2.7.3

INSTALLATION ................................. 9-15

9-2.8

TILT CYLINDER...................................... 9-15

9-2.8.1

REMOVAL ......................................... 9-15

9-2.8.2

REPAIR ............................................. 9-15

Summary of Contents for PDSR 30

Page 1: ...Big Lift LLC MANUAL NO BL PDSR 30 0319 03 07 2019 www bigjoeforklifts com PDSR 30 POWER DRIVE REACH LIFT TRUCK Operation Maintenance Repair Parts List ...

Page 2: ......

Page 3: ...1 7 HORN SWITCH REPLACEMENT 5 4 5 1 8 LIFT AND LOWER SWITCH REPLACEMENT 5 4 5 2 COMPARTMENT COVERS 5 4 5 2 1 REMOVAL 5 4 5 2 2 INSTALLATION 5 4 5 3 STEERING ARM 5 4 5 3 1 RETURN SPRING REPLACEMENT 5 4 5 3 2 STEERING ARM REMOVAL 5 4 5 3 3 STEERING ARM INSTALLATION 5 4 6 BRAKE SERVICING 6 1 6 1 BRAKES 6 1 6 1 1 AIR GAP ADJUSTMENT 6 1 6 1 2 STOPPING DISTANCE ADJUSTMENT 6 2 6 1 3 BRAKE ASSEMBLY REPLAC...

Page 4: ...1 ELECTRICAL CONTROL PANEL 10 1 10 1 1 MAINTENANCE 10 1 10 1 2 CLEANING 10 1 10 1 3 PANEL REMOVAL 10 1 10 1 4 PANEL DISASSEMBLY 10 1 10 1 5 PANEL INSTALLATION 10 1 10 2 HORN REPLACEMENT 10 1 10 3 PUMP MOTOR 10 5 10 4 DRIVE MOTOR 10 5 10 5 DEADMAN SWITCH 10 5 11 OPTIONAL EQUIPMENT 11 1 11 1 LOAD BACKREST 11 1 12 ILLUSTRATED PARTS BREAKDOWN 12 1 ...

Page 5: ... Figure 1 2 lifts and transp orts payloads up to 3000 pounds on rigid forks 4 feet without changing the overall lift height Then the mast will start to rise However if the truck has an optional load backrest the backrest will raise above the mast before the end of the full free lift The forward and reverse motion is controlled by either of two controller levers mounted on the control head Stopping...

Page 6: ...it switch to restrict speed when lift carriage is raised above the preset limit All control functions automatically return to OFF when released Externally accessible battery disconnect within oper ator s reach Separately fused control circuits and power circuits Readily accessible horn button Lift carriage backrest to help stabilize the load Handle to provide a firm hand hold for operator Flow con...

Page 7: ...re 1 2 PDSR Lift Truck Pos Component Pos Component 1 CONTROL HANDLE 7 FORKS 2 WINDSHIELD 8 COVER 3 LIFT CYLINDER 9 STABILIZERS 4 KEY SWITCH 10 DRIVE WHEEL 5 BATTERY INDICATOR 11 BATTERY PLUG 6 EMERGENCY DISCONNECT 12 REACH ASSEMBLY R3930 ...

Page 8: ...1 4 BL PDSR 30 0319 03 07 2019 NOTES ...

Page 9: ...the truck has a firm and level footing Avoid overhead wires and obstructions Check for obstructions when raising or lowering the lift carriage Do not handle unstable or loosely stacked loads Use special care when handling long high or wide loads to avoid tipping loss of load or striking bysta nders Center and carry the load as far back as possible toward the lift carriage back rest The center of g...

Page 10: ...t they are prop erly secured Chains cables and hoses Check that they are in place secured correctly functioning properly and free of binding or damage Guards and load backrest Check that safety guards are in place properly secured and not damaged Safety signs Check that warning labels nameplate etc are in good condition and legible Horn Check that horn sounds when operated Steering Check for bindi...

Page 11: ...BL PDSR 30 0319 03 07 2019 2 3 Figure 2 2 Sample of Operator Check List R3815 ...

Page 12: ...ing or stopping the truck 5 Procedures for movement in reverse are the same as in the forward direction except slowly press the speed control backward 2 5 1 Stopping The stopping distance of the truck depends on the ground conditions The driver must take this into account when operating the truck The driver must be looking ahead when traveling If there is no hazard brake moderately to avoid moving...

Page 13: ...wer Control buttons are located on the steering control head Figure 2 4 To lift forks push in either LIFT button and hold until forks reach desired height To lower forks push in either LOWER button and hold until forks descend to desired height 2 9 LOADING AND UNLOADING 1 Move truck to location where load is to be picked up 2 Move the truck into position so forks are within pallet or skid and the ...

Page 14: ...2 6 BL PDSR 30 0319 03 07 2019 NOTES ...

Page 15: ...ubbling stops neutralizes the acid for safe hand ing and disposal Leakage voltage from battery terminals to battery case can cause misleading trouble symptoms with the truck electrical system Since components of the truck electrical system are insulated from truck frame leakage voltage will not normally affect truck operation unless a short circuit or breakdown of circuit wire insulation to truck ...

Page 16: ... in areas designated for that use 2 Make certain the charger being used matches the voltage and amperage of the truck battery 3 Before disconnecting or connecting batteries to a charger make sure the charger is OFF If an attempt is made to do this while the charger is ON serious injury to you the battery and the charger could result 4 Before connecting the battery cable to the trucks receptacle ma...

Page 17: ...harger being used 3 5 LUBRICATION Refer to Table 3 2 for the recommended types of grease and oil Table 3 3 in conjunction withFigure 3 1 identifies the items requiring lubrication 3 6 LIFT CHAIN MAINTENANCE Fully raise and lower lift carriage while observing chains as they move over chain sheaves Ensure chain is aligned and tracking properly and all links are pivoting freely With lift carriage ful...

Page 18: ...iters Can No 1 Fill to level plug opening 2 Inner Outer Mast Brush No 2 Full length of channel where rollers operate 3 Hydraulic Reservoir Capacity 13 78 Liters L H 2600mm Capacity 14 91 Liters L H 3200mm Capacity 16 86 Liters L H 4000mm Can No 3 With lift carriage fully lowered fill res ervoir with hydraulic oil to 1 inch below opening 4 Lift Chain Brush or Spray No 4 See Paragraph 3 6 R8124 ...

Page 19: ...s key switch to determine if it is malfunctioning e Emergency brake switch defective Bypass the switch to determine if it is malfunctioning f Defective wiring Check for open circuit Repair as required TRUCK DOES NOT OPERATE FORWARD OR REVERSE Truck does not travel forward or reverse All other functions operate normally a Check all wiring A loose connec tion may be the cause of mal function Tighten...

Page 20: ...t stopping distance adjust ment Adjust b Defective electric brake Replace Abnormal noise and chatter when brake is applied Defective electric brake Replace TROUBLE WITH LIFTING OR LOWERING Oil sprays or flows from the top of the lift cylinder Defective packing in lift cylinder Repair lift cylinder Squealing sounds when lifting forks a Oil level too low Identify oil leak and fill reservoir b Lift l...

Page 21: ...uns a Oil level too low Add oil to reservoir b Load larger than capacity Refer to nameplate on side of mast for maximum load capacity c Incorrect stopping distance adjust ment Change batteries Forks creep downward under load when in a raised position Leak in hydraulic system lift cylinder or lowering valve Check for leaking fitting in hydrau lic line and repair as required Repack lift cylinder or ...

Page 22: ... function permits a deeper diagnosis of problems as the recent history can be revisited 4 2 2 2 Logbook Access To view the alarm logbook proceed as follows 1 Connect the Zapi Handset refer to paragraph 4 2 1 2 Press the ROLL down button and the ENTER button at the same time to enter the MAIN MENU 3 Press the ROLL down button or the ROLL up but ton to find the ALARMS display 4 Press the ENTER butto...

Page 23: ...wd and Rev are active at the same time Check the wiring of the Fwd and Rev travel demand inputs use the readings in the TESTER to facilitate the trouble shooting Check the micro switches for failures A failure in the logic is possible too So when you have verified the travel demand switches and wiring are cor rect it is necessary to replace the con troller 79 INCORRECT START This is a warning for ...

Page 24: ...k will work with the default values Try to execute a CLEAR EEPROM operation refer to CONSOLE manual Switch the key off and on to check the result If the alarm occurs permanently it is necessary to replace the controller If the alarm disappears the previously stored parameters will have been replaced by the default parameters with the temperature increases from 85 C to 105 C 65 MOTOR TEMPERATURE Th...

Page 25: ...ues which means the maxi mum current adjustment pro cedure has not been carried out yet Ask the assistance of a Zapi technician to do the correct adjustment procedure of the current gain parameters 68 WAITING FOR NODE The controller receives from the CAN the message that another controller in the net is in fault condition as a conse quence the ACOE controller itself cannot enter an operative statu...

Page 26: ...urrent feedback sensor is not con stantly stuck to 0 Check the motor connection that there is continuity If the motor connec tion is opened the current cannot flow so the test fails and the error code is displayed If everything is ok for what it concerns the motor the problem could be in the current sensor or in the related circuit 75 CONT DRV EV1 The EV1 valve driver is not able to drive the load...

Page 27: ...ence Check the wirings Check the micro switches It could also be an error sequence made by the operator A fail ure logic is possible too When all of the above conditions were checked and nothing was found replace the control ler 90 PUMP VACC RANGE The voltage on CNC 9 is outside of the parameters range If the EVP TYPE parameter is set to ANALOG please acquire again the val ues of MIN LOWER and MAX...

Page 28: ...eplace the controller 17 LOGIC FAILURE 3 This alarm occurs in the rest state if the output of the voltage amplifier of the phase Vu Vw have a drift larger than 0 25 V It is necessary to replace the controller 18 LOGIC FAILURE 2 This alarm occurs when the real voltage between phases W and V of the motor is different from the desired voltage It is necessary to replace the controller 19 LOGIC FAILURE...

Page 29: ...ning Check the motor is suited to work with the EPS DC0 not oversized Other wise it is necessary to replace the con troller 71 POWER FAILURE 3 This alarm occurs when the cur rent in the phase V of the motor is zero and the motor is com manded for moving Check the power fuse is OK Check the battery positive arrives to the controller Check the continuity of the wire in the phase V of the motor Other...

Page 30: ...open the voltage on CNA 4 is expected to be close to 0 Vdc and this is independent from whether the safety contacts are connected to a plus battery or to a minus battery In the first case safety contacts connected to a plus battery when the safety con tacts are open CNA 4 is connected to a minus battery through a load Only a harness mistake may connect NK1 to a higher than 12 voltage 212 MICRO SLA...

Page 31: ...er has not reached its own electrical limit because of too much angle of the steered wheel Besides this alarm may occur at the installation when the motor rotates in the wrong direction turning away from the desired direction 223 JERKING FB POT This alarm occurs if the feedback potentiometer CPOT on CNB 6 changes with a jerk larger than 0 3V in 16 msec This alarm is used to catch a discontinuity i...

Page 32: ...sor bearing has two rings one is connected to the rotor shaft the other is connected to the motor frame Check these two rings are securely connected to their structure without slip page 238 EPS NOT ALIGNED This is a real alarm that cuts off the traction It occurs at the initial align ment if the straight ahead condition is not matched within 6 sec Throughout the 6 sec delay steering is not activat...

Page 33: ...ions If the values in these thee location are diffe rent this alarm occurs It is necessary to send the controller to Zapi to execute the maximum current regulation 245 DATA ACQUISITION This alarm occurs when acquiring the motor resistance or when adjust ing the parameters to compensate for the gain of the current amplifiers maximum current factory adjusted Recycle the key 246 MICRO SLAVE KO In ste...

Page 34: ... necessary to replace the controller 251 KM OPEN This alarm occurs if the slave uC detects the safety contact of the main uC o pen when expected being closed It is necessary to replace the controller 252 KS OPEN This alarm occurs if the slave uC detects the safety contact of the main uC open when expected being closed It is necessary to replace the controller 253 KM CLOSED This alarm occurs at key...

Page 35: ...BL PDSR 30 0319 03 07 2019 4 17 Figure 4 2 Wiring Diagram R8126 ...

Page 36: ...4 18 BL PDSR 30 0319 03 07 2019 NOTES ...

Page 37: ...stall three screws three washers and three flat wash ers 2 Reconnect harness to potentiometer and switch 3 Install the cap assembly as described in para graph 5 1 2 5 1 5 Potentiometer Replacement 1 Remove the cap assembly as described in para graph 5 1 1 2 Disconnect harness from potentiometer 3 Remove screw washer and control knob from potentiometer 4 Remove screw washer and control knob from ot...

Page 38: ...5 2 BL PDSR 30 0319 03 07 2019 Figure 5 1 Control Head Assembly DR_0007 ...

Page 39: ...BL PDSR 30 0319 03 07 2019 5 3 Figure 5 2 Steering Arm DR_0006 ...

Page 40: ...s 3 Close covers 4 Install two screws and two washers 5 Disengage the emergency stop switch and turn on key switch 5 3 STEERING ARM 5 3 1 Return Spring Replacement The steering arm gas return spring is replaced while the steering arm is in the upright position 1 Engage the emergency stop switch and turn off key switch 2 Secure the steering arm in the upright position 3 Remove screw and free the ga...

Page 41: ... truck to its top speed on an even dry concrete surface Move control handle into the lower braking position Measure length of braking path from the actuation point of the brakes until the truck has stopped The actual length of the braking path should be between approximately 1 5 2 5 ft 0 5 0 7 m if more than that replace the brake 6 1 3 TBrake Assembly Replacement 1 Block load wheels 2 Remove the ...

Page 42: ...6 2 BL PDSR 30 0319 03 07 2019 NOTES ...

Page 43: ...ff key switch 2 Remove the compartment covers as described in paragraph 5 2 3 Disconnect encoder from harness 4 Remove three screws and encoder from the steering motor 5 Disconnect harness from steering motor 6 Remove screw lock washer washer and gear from steering motor 7 Remove four screws and lift steering motor from the frame 8 Install new steering motor by reversing the steps above 7 4 Load W...

Page 44: ...tall bearings in load wheel 2 Position load wheel in the straddle 3 Install shaft and secure with screws and retaining ring 4 Remove blocking from under the truck 5 Lower the forks 6 Disengage the emergency stop switch and turn on key switch Figure 7 1Transmission Motor Brake Mounting Figure 7 2 Load Wheel DR_0004 R8128 ...

Page 45: ...rriage 2 Engage the emergency stop switch and turn off key switch WARNING Before attempting any adjustment make certain power is disconnected 3 Loosen both upper jam nuts to allow for adjust ment of middle jam nuts 4 Break both lower jam nuts free from the middle jam nuts 5 Take up slack in both lift chains with middle jam nuts Strive for equal tension on both chains 6 Align anchor so the clevis p...

Page 46: ...Telescopic 1 With the lift truck wheels securely blocked raise the forks approximately three feet from floor and position blocks or strong supports under inner mast 2 Lower inner mast onto the support Check that arrangement is secure before proceeding WARNING Before attempting any adjustment make certain power is disconnected 3 Engage the emergency stop switch and turn off key switch 4 Remove cott...

Page 47: ...BL PDSR 30 0319 03 07 2019 8 3 Figure 8 2 Telescopic Mast Assembly DR_0029 ...

Page 48: ...ng to paragraph 8 2 11 Disengage the emergency stop switch and turn on key switch 8 4 3 TRIMAST Secondary Lift Chain 1 With the lift truck wheels securely blocked raise the forks approximately three feet from floor and position blocks or strong supports under masts 2 Lower inner mast onto the support Check that arrangement is secure before proceeding 3 Engage the emergency stop switch and turn off...

Page 49: ...BL PDSR 30 0319 03 07 2019 8 5 Figure 8 3 Trimast Assembly DR_0014 ...

Page 50: ...8 6 BL PDSR 30 0319 03 07 2019 NOTES ...

Page 51: ...mediately Provide a container under the line or fitting before discon necting 4 Telescopic Trucks Refer to Figure 9 1 or Fig ure 9 1 1 and re move leaking line or fitting and replace it with a new line or fitting TRIMAST Trucks Refer to Figure 9 2 or Figure 9 2 1 and re move leaking line or fitting and replace it with a new line or fitting 5 Check level of hydraulic oil With lift carriage fully lo...

Page 52: ...9 2 BL PDSR 30 0319 03 07 2019 Figure 9 1 Hydraulic Lines for Telescopic Lift Cylinder DR_0032 ...

Page 53: ...BL PDSR 30 0319 03 07 2019 9 3 Figure 9 1 1 Hydraulic Lines for Telescopic Mast DR_0033 ...

Page 54: ...9 4 BL PDSR 30 0319 03 07 2019 Figure 9 2 Hydraulic Lines for Trimast Lift Cylinder DR_0021 ...

Page 55: ...BL PDSR 30 0319 03 07 2019 9 5 Figure 9 2 1 Hydraulic Lines for Trimast DR_0022 ...

Page 56: ... 10 3 and Figure 10 4 5 Disconnect hoses from pump motor assembly 6 While supporting the pump motor assembly remove four screws and four lock washers 7 Remove the pump motor assembly 9 2 2 Disassembly and Reassembly 1 Remove the hydraulic pump motor assembly as described in paragraph 9 2 1 2 Refer to Figure 9 3 for disassembly and reas sembly 9 2 3 Installation 1 While supporting the pump motor as...

Page 57: ...ns clear of sheaves and lay them aside WARNING Support lift cylinder before performing the following steps to prevent cylinder from falling 9 Tilt lift cylinder forward from their position in the lift truck 10 Raise lift cylinder assembly up and out of truck 9 2 4 2 Repair CAUTION To prevent damage use proper pipe clamp vise The cylinder will be distorted if the vise is tightened too much 1 Secure...

Page 58: ...ted 3 Using another lift truck or suitable jack raise lift carriage far enough to remove pressure on the free lift cylinder 4 Remove cotter pin and clevis pin connecting chain to chain anchor at free lift cylinder 5 Remove chains from sheaves 6 Remove screw lock washer flat washer bracket and ram head from cylinder CAUTION Hydraulic oil can damage parts Wipe off any oil immediately Provide a conta...

Page 59: ...nt make certain power is disconnected 3 Remove screw lock washer and flat washer securing the top of cylinder to mast 4 Using another lift truck or suitable jack raise mid dle mast far enough to remove pressure on the secondary lift cylinder CAUTION Hydraulic oil can damage parts Wipe off any oil immediately Provide a container under the line or fitting before discon necting 5 Support cylinder and...

Page 60: ...ttempting any replacement make certain power is disconnected CAUTION Hydraulic oil can damage parts Wipe off any oil immediately Provide a container under the line or fitting before discon necting 3 Disconnect the hose from the reach cylinder WARNING Support reach cylinder before perform ing the following steps to prevent cylinder from falling 4 Remove screw shaft from the scissors base 5 Remove s...

Page 61: ...BL PDSR 30 0319 03 07 2019 9 11 Figure 9 8 Hydraulic Lines for Reach Assembly DR_0023 ...

Page 62: ...9 12 BL PDSR 30 0319 03 07 2019 Figure 9 9 Telescopic Reach Assembly DR_0030 ...

Page 63: ...BL PDSR 30 0319 03 07 2019 9 13 Figure 9 10 1 Trimast Reach Assembly DR_0015 ...

Page 64: ...sors assem bly CAUTION Hydraulic oil can damage parts Wipe off any oil immediately Provide a container under the line or fitting before discon necting 4 Disconnect the hose from the reach cylinder WARNING Support tilting cylinder before performing the following steps to prevent cylinder from falling 5 Remove two screws lock washer and flat washer from the fork weldment 6 Remove cylinder and out of...

Page 65: ...BL PDSR 30 0319 03 07 2019 9 15 Figure 9 12 Telescopic System DR_0028 ...

Page 66: ...9 16 BL PDSR 30 0319 03 07 2019 Figure 9 13 Trimast System DR_0013 ...

Page 67: ...le lifting device support the shifter side assembly 4 Position the shifter side assembly with two screws and shafts and remove the supports 5 Operate the tilting button to refill the cylinder and lines with hydraulic oil 6 Check level of hydraulic oil If required add hydraulic oil to bring to proper level Use hydraulic oil listed in Table 3 2 7 Install the compartment covers as described in paragr...

Page 68: ...9 18 BL PDSR 30 0319 03 07 2019 NOTES ...

Page 69: ...ea The controller should be wiped clean with a moist rag Allow it to dry before reconnecting the battery 4 Make sure the connections to the buss bars are tight Use two well insulated wrenches for this task in order to avoid steering the buss bars 10 1 3 Panel Removal 1 Engage the emergency stop switchand turn off key switch 2 Remove the compartment covers as described in paragraph 5 2 3 Tag and di...

Page 70: ...10 2 BL PDSR 30 0319 03 07 2019 DR_0009 ...

Page 71: ...BL PDSR 30 0319 03 07 2019 10 3 Figure 10 1 Electrical System DR_0010 ...

Page 72: ...10 4 BL PDSR 30 0319 03 07 2019 Figure 10 2 Control Panel Assembly DR_0011 ...

Page 73: ...ld be cleaned at least once a month to assure proper cooling of motor Use an air hose to blow dust off of motor sur faces The drive motor is replaceable but not repairable Refer to paragraph 7 2 10 5 DEADMAN SWITCH 1 Disconnect harness from the deadman switch 2 Remove the two screws and switches from bracket 3 Position the new switches on bracket and secure with the two screws 4 Reconnect harness ...

Page 74: ...10 6 BL PDSR 30 0319 03 07 2019 NOTES ...

Page 75: ...BL PDSR 30 0319 03 07 2019 11 1 SECTION 11 OPTIONAL EQUIPMENT 11 1 LOAD BACKREST A load backrest is available for addition to the lift truck to allow handling of high loads ...

Page 76: ...11 2 BL PDSR 30 0319 03 07 2019 NOTES ...

Page 77: ...BL PDSR 30 0319 03 07 2019 12 1 SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the PDSR Lift Truck ...

Page 78: ...12 2 BL PDSR 30 0319 03 07 2019 Figure 12 1 Frame DR_0001 ...

Page 79: ... M16 80 4 5 0000 000191 00 LOCKWASHER Ø16 4 6 0000 000220 00 FLATWASHER Ø16 4 7 0000 000228 00 BOLT M12 25 4 8 0000 000060 00 LOCKWASHER Ø12 8 9 0000 000222 00 FLATWASHER Ø12 4 10 0000 000181 00 BEARING 8 11 2130 140001 00 LOAD WHEEL 4 12 2130 140003 00 WASHER 8 T 1 13 2130 140002 0A SHAFT 4 14 0000 000654 00 ROLL PIN Ø4 45 4 15 0000 000294 00 RETAINING RING Ø25 4 16 0000 000428 00 BOLT M6 30 2 17...

Page 80: ...12 4 BL PDSR 30 0319 03 07 2019 Figure 12 2 Cover Assembly DR_0002 ...

Page 81: ...a 2415 100200 1B COVER R 1 Used from serial number 326110026 9 1220 150005 00 CLASP NUT M8 3 10 0000 000322 00 SCREW M8 25 4 11 0000 000159 00 LOCKWASHER Ø8 10 12 0000 000194 00 FLATWASHER Ø8 9 13 3218 210001 00 SHOCK ABSORBER 1 14 2214 150002 00 WASHER 3 15 0000 000649 00 SCREW M8 20 2 16 1220 520010 0C FAN 1 17 1220 500004 00 FAN GUARD 1 18 0000 000121 00 SCREW M4 35 4 19 0000 000122 00 LOCKWASH...

Page 82: ...12 6 BL PDSR 30 0319 03 07 2019 Figure 12 3 Battery Compartment DR_0003 ...

Page 83: ... B0 ROLLER 5 Used on trucks with Lift Height 189 7 2130 151000 00 BATTERY ROLLER TRAY 1 Used up to serial number 324200105 Does NOT include rollers 7a 2415 111000 00 BATTERY ROLLER TRAY 1 Used from serial number 324200106 Does NOT include rollers 7b 2415 111000 B0 BATTERY ROLLER TRAY 1 Used on trucks with Lift Height 189 Does NOT include rollers 8 0000 000321 00 SCREW M8 20 2 9 0000 000194 00 FLAT...

Page 84: ...12 8 BL PDSR 30 0319 03 07 2019 Figure 12 4 Transmission Motor Brake Assembly Used up to serial number 325130600 DR_0004 ...

Page 85: ... II 1 With Sensor 7 0000 000056 00 LOCKWASHER Ø6 1 8 0000 000386 00 SCREW M6 20 1 9 0000 000321 00 SCREW M8 20 4 10 0000 000159 00 LOCKWASHER Ø8 8 11 1221 240000 0A STEERING MOTOR 1 12 1221 200004 00 GEAR 1 13 1221 200005 00 WASHER 1 14 0000 000208 00 SCREW M4 25 3 15 3712 403000 00 ENCODER 1 16 1221 240001 0A BRUSH STEERING MOTOR 4 17 2415 220000 10 GEAR CASE ASSEMBLY 1 18 2415 230000 10 DRIVE WH...

Page 86: ...12 10 BL PDSR 30 0319 03 07 2019 Figure 12 5 Transmission Motor Brake Assembly Used from serial number 325130601 DR_0040 ...

Page 87: ...159 00 LOCKWASHER Ø8 8 11 1221 240000 0A STEERING MOTOR 1 12 1221 200004 00 GEAR 1 13 1221 200005 00 WASHER 1 14 0000 000208 00 SCREW M4 25 3 15 3712 403000 00 ENCODER 1 16 1221 240001 0A BRUSH STEERING MOTOR 4 17 2415 220000 1A GEAR CASE ASSEMBLY 1 Used between serial number 325130601 and 326140301 17a ZK18 240000 A0 02 GEAR CASE ASSEMBLY 1 Used from serial number 326140302 18 2415 230000 1A DRIV...

Page 88: ...12 12 BL PDSR 30 0319 03 07 2019 Figure 12 6 Gear Case Assembly Used up to serial number 326140301 DR_0005 ...

Page 89: ...7 00 SCREW M6 12 14 13 2415 GB10 10 GEAR 1 The kit includes 2 gears 14 0000 000379 00 FLATWASHER Ø14 1 15 0000 001055 00 WASHER Ø14 1 16 0000 001056 00 NUT M14 1 5 1 17 2415 220014 10 SEAL WASHER TC100 150 13 1 18 2415 220003 10 DRIVE SHAFT 1 Used up to serial number 325130600 18a 2415 220003 1A DRIVE SHAFT 1 Used between serial number 325130601 and 326140301 19 2415 220018 10 COVER PLATE 1 20 241...

Page 90: ...12 14 BL PDSR 30 0319 03 07 2019 Figure 12 7 Gear Case Assembly Used from serial number 326140302 DR_0044 ...

Page 91: ... 0000 001056 00 NUT M14 1 5 2 15 0000 000070 00 SCREW M10 25 6 16 0000 000379 00 FLATWASHER Ø14 1 17 0000 001055 00 WASHER Ø14 1 18 ZK18 240008 00 COVER 1 19 0000 000056 00 LOCKWASHER Ø6 22 20 0000 000077 00 SCREW M6 12 14 21 0000 000055 00 SCREW M6 16 8 22 0000 001054 00 BEARING 2 23 ZK18 240005 00 COVER 1 24 3060 020000 28 O RING 155 4 1 25 ZK18 240003 00 GEAR CASE 1 26 ZK18 GB00 10 GEAR KIT Z1 ...

Page 92: ...12 16 BL PDSR 30 0319 03 07 2019 Figure 12 8 Steering Arm DR_0006 ...

Page 93: ...20 0000 000159 00 LOCKWASHER Ø8 16 21 0000 000433 00 SCREW M8 12 1 22 2322 310000 00 BRACKET 1 23 0000 000283 00 BOLT M10 35 4 24 0000 000007 00 FLATWASHER Ø10 4 25 0000 000063 00 LOCKWASHER Ø10 5 26 0000 000553 00 NUT M10 4 27 2322 300001 0A STEERING SHAFT 1 28 0000 000882 00 C TYPE KEY 8 7 14 1 29 1280 370000 10 DAMPING STEERING BOX 1 30 0000 000176 00 FLATWASHER Ø8 11 31 0000 000321 00 SCREW M8...

Page 94: ...12 18 BL PDSR 30 0319 03 07 2019 Figure 12 9 Control Head Assembly DR_0007 ...

Page 95: ... 2415 340004 00 TILT SWITCH WIRE 1 13 2333 340017 00 CLAMP 4 14 2333 340009 00 MOUNTING SEAT 2 15 2333 340012 00 SCREW ST2 9 9 5 2 16 2333 340010 00 SPRING 1 17 0000 000037 00 SCREW M3 12 2 18 0000 000038 00 LOCK WASHER Ø3 2 19 2333 340013 00 SCREW M5 30 2 20 2333 340014 00 SCREW M5 55 2 21 2333 340008 00 LIFT LOWERING SWITCH 1 22 2333 340016 00 SIDE SHIFT SWITCH 1 23 2415 340008 00 SIDE SHIFT SWI...

Page 96: ...12 20 BL PDSR 30 0319 03 07 2019 Figure 12 10 Hydraulic System DR_0008 ...

Page 97: ...0000 000176 00 FLATWASHER Ø8 5 8 2112 410004 00 WASHER 3 9 2415 411000 10 TANK 1 10 0000 000510 00 WASHER Ø20 1 11 0000 000635 00 PLUG M18 1 5 1 12 2415 438000 10 OIL PIPE SIDE SHIFT 2 13 2415 439000 10 OIL PIPE LIFT 1 14 2702 141400 00 CONNECTOR G1 4 M14X1 5 2 15 0000 000044 00 WASHER Ø14 2 16 2702 141600 00 CONNECTOR G1 4 M16X1 5 1 17 0000 000069 00 WASHER Ø16 1 18 2130 423000 00 FILTER 1 Used u...

Page 98: ...12 22 BL PDSR 30 0319 03 07 2019 Figure 12 11 Triple Solenoid Valve DR_0045 ...

Page 99: ... 07 2019 12 23 TRIPLE SOLENOID VALVE Pos Part Number Description Qty Reqd Notes 1 2415 441100 30 1 2 2415 441200 30 6 Pos 3 7 3 2415 441201 30 1 4 2415 441202 30 1 5 2415 441203 30 1 6 2415 441204 30 1 7 2415 441205 30 2 ...

Page 100: ...12 24 BL PDSR 30 0319 03 07 2019 Figure 12 12 Pump and Motor Assembly DR_0037 ...

Page 101: ...ALVE 3 13 2415 450013 10 PROPORTIONAL SOLENOID VALVE 1 14 2415 450014 10 HYDRAULIC LOCK 1 15 2415 450015 10 ADAPTER 1 16 2415 450016 10 RELIEF VALVE 1 17 2415 450017 10 PROPORTIONAL COMPENSATING VALVE 1 18 2415 450018 10 MOTOR BRUSH 1 19 0000 000110 00 SCREW M8 65 2 20 0000 000159 00 LOCKWASHER Ø8 2 21 2415 450019 10 O RING 19 2 4 2 22 2415 450020 10 O RING 16 36 2 21 1 23 2415 450021 10 O RING 24...

Page 102: ...12 26 BL PDSR 30 0319 03 07 2019 Figure 12 13 Electrical System DR_0009 ...

Page 103: ...00433 00 SCREW M8 12 4 7 0000 000159 00 LOCKWASHER Ø8 4 8 0000 000105 00 FLATWASHER Ø8 4 9 1120 500003 00 HORN 1 10 1220 520002 1C KEY SWITCH ASSEMBLY 1 11 1120 112008 00 PLATE 1 12 0000 000056 00 LOCKWASHER Ø6 5 13 1220 500001 00 EMERGENCY DISCONNECT 1 14 0000 000119 00 SCREW M5 12 2 15 0000 000738 00 SCREW M8 30 1 16 2322 560001 20 BAFFLE BLOCK 1 17 0000 000550 00 NUT M8 1 18 0000 001678 00 BOLT...

Page 104: ...12 28 BL PDSR 30 0319 03 07 2019 Figure 12 14 Proportional Valve Circuit Board DR_0039 ...

Page 105: ... Used from Serial Number 325150188 2 0000 001138 00 SCREW 2 Used from Serial Number 325150188 3 0000 000924 00 NUT M3 2 Used from Serial Number 325150188 4 2415 520004 20 CIRCUIT BOARD 1 Prior to Serial Number 325150188 it was mounted without the box by the Drive motor 5 2415 100300 10 CIRCUIT BOARD BOX 1 Used from Serial Number 325150188 ...

Page 106: ...12 30 BL PDSR 30 0319 03 07 2019 Figure 12 15 Control Panel Assembly DR_0010 ...

Page 107: ...000015 00 SCREW M6 10 8 6 1120 530006 00 COPPER CONDUCTOR 1 7 2415 530012 2A CONTROLLER 1 8 1120 500005 10 CONTACTOR 1 9 0000 000196 00 NUT M8 2 10 0000 000210 00 FLATWASHER Ø8 3 11 1120 540002 00 FUSE 200A 1 12 0000 000074 00 SCREW M6 20 2 13 1120 540001 00 STAND 1 14 0000 000128 00 FLATWASHER Ø5 2 15 0000 000206 00 LOCKWASHER Ø5 2 16 0000 000031 00 SCREW M5 8 2 17 1280 560002 10 70 CONTROLLER 1 ...

Page 108: ...12 32 BL PDSR 30 0319 03 07 2019 Figure 12 16 Wiring Harness DR_0011 ...

Page 109: ... Lift Height 189 4 2415 520005 00 01 POWER CHAIN WIRING HARNESS 1 Used up to Serial Number 325150404 for Lift Height 102 4a 2415 520005 0A 03 POWER CHAIN WIRING HARNESS 1 Used up to Serial Number 325150404 for Lift Height 106 4b 2415 520005 00 02 POWER CHAIN WIRING HARNESS 1 Used up to Serial Number 325150404 for Lift Height 126 4c 2415 520005 2A 07 POWER CHAIN WIRING HARNESS 1 Used up to Serial N...

Page 110: ...12 34 BL PDSR 30 0319 03 07 2019 Figure 12 17 Travel Alarm Wiring Harness DR_0041 ...

Page 111: ...BL PDSR 30 0319 03 07 2019 12 35 TRAVEL ALARM WIRING HARNESS Pos Part Number Description Qty Reqd Notes 1 2415 521002 B0 TRAVEL ALRM WIRING HARNESS 1 Travel Alarm is Optional ...

Page 112: ...12 36 BL PDSR 30 0319 03 07 2019 Figure 12 18 Cable Assembly DR_0012 ...

Page 113: ...R LINE W 1 2 2415 530002 2A MOTOR LINE V 1 3 2415 530001 2A MOTOR LINE U 1 4 2415 530006 2A STEERING MOTOR LINE U 1 5 2415 530007 20 STEERING MOTOR LINE W 1 6 2415 530013 2A EMERGENGY STOP LINE 1 7 2415 530004 00 PUMP POWER LINE 1 8 2415 530005 00 PUMP POWER LINE 1 9 2415 530009 20 CONTROLLER TO CONTROLLER LINE 1 ...

Page 114: ...12 38 BL PDSR 30 0319 03 07 2019 Figure 12 19 Trimast System Assemblies DR_0013 ...

Page 115: ...2000 10 ROLLER ASSEMBLY 4 5 2415 640004 10 SELF LUBRICATING BEARING 2 6 2415 640400 10 SHAFT 2 7 0000 000277 00 BOLT M8X25 2 8 0000 000159 00 LOCKWASHER Ø8 2 9 0000 000176 00 FLATWASHER Ø8 2 10 2415 640012 10 01 WASHER A R As Required 2mm 10a 2415 640012 10 02 WASHER A R As Required 3mm 11 2415 612001 10 SCREW 4 12 2415 612002 10 SNAP RING 4 13 2415 612003 10 ASSISTANT ROLLER 4 14 2415 612004 10 M...

Page 116: ...12 40 BL PDSR 30 0319 03 07 2019 Figure 12 20 Trimast Assembly DR_0014 ...

Page 117: ...11 0000 000222 00 FLATWASHER Ø12 8 12 2415 600005 1A MIDDLE HOSE PULLEY 1 13 2415 600006 1A BUSHING 2 14 0000 001413 00 BOLT M12 100 2 15 0000 000165 00 NUT M12 1 16 0000 000210 00 FLATWASHER Ø8 2 17 2415 600013 10 MIDDLE CYLINDER BLOCK 2 18 0000 001416 00 BOLT M12X60 2 19 2415 421000 10 LIFTING WELDMENT 1 20 2415 600001 10 DRAG CHAIN LOWER TIE PLATE 1 21 0000 000089 00 FLATWASHER Ø4 4 22 0000 000...

Page 118: ...12 42 BL PDSR 30 0319 03 07 2019 Figure 12 20 Trimast Assembly Continued DR_0014 ...

Page 119: ...0100 10 WELDMENT 1 50 2415 600015 10 CYLINDER BRACKET 2 51 0000 000191 00 LOCKWASHER Ø16 4 52 2415 600016 1A LIMIT SWITCH PLATE 1 53 0000 000118 00 SCREW M8X10 6 54 2125 500003 00 PROXIMITY SWITCH 2 55 2415 600018 10 SENSOR BRACKET 1 56 0000 000117 00 SCREW M5X10 6 57 0000 000206 00 LOCKWASHER Ø5 6 58 0000 000390 00 FLATWASHER Ø5 6 59 2415 520007 2B 08 LIFT LIMIT PROXIMITY SWITCH WIRING 1 Used for...

Page 120: ...12 44 BL PDSR 30 0319 03 07 2019 Figure 12 21 Option for Trimast 189 DR_0042 ...

Page 121: ...001 B0 WARNING LIGHT WIRING 1 Option for the travel alarm 3 2333 500001 50 BRACKET 1 Option for the travel alarm 4 0000 000176 00 FLAT WASHER Ø8 6 5 0000 000159 00 LOCK WASHER Ø8 6 6 0000 000109 00 SCREW M8 16 6 7 0000 000702 00 FLAT WASHER Ø4 2 8 0000 000122 00 LOCK WASHER Ø4 2 9 0000 000139 00 NUT M4 2 10 2415 611000 B0 EXTERNAL MAST 1 189 4800mm for the travel alarm ...

Page 122: ...12 46 BL PDSR 30 0319 03 07 2019 Figure 12 22 Trimast Reach Assembly DR_0015 ...

Page 123: ...7 2415 642201 10 EXTERNAL SCISSORS MAIN ROLLER 2 18 2415 642202 10 SLIDER 2 19 2415 642203 10 RETAINER RING Ø55 3 20 2415 642204 10 SCREW M10X1X12 2 21 2415 642205 10 SCREW M10X1X16 2 22 2415 643201 10 INTERNAL SCISSORS MAIN ROLLER 2 23 2415 643202 10 SLIDER 2 24 2415 643203 10 RETAINER RING Ø34 2 25 2415 643204 10 SCREW M10X1X14 2 26 2415 643205 10 SCREW M10X1X16 2 27 2415 640300 10 SHORT PIN WEL...

Page 124: ...12 48 BL PDSR 30 0319 03 07 2019 Figure 12 22 Trimast Reach Assembly Continued DR_0015 ...

Page 125: ... Number Description Qty Reqd Notes 40 2415 600014 10 COVER 1 41 0000 000028 00 BOLT M4X10 3 42 0000 000122 00 LOCKWASHER Ø4 3 43 0000 000089 00 FLATWASHER Ø4 3 44 3316 610001 10 FIXED BLOCK 2 45 0000 000988 00 BOLT M6X30 2 46 2415 640010 1A WASHER 2 47 2415 640011 10 WASHER 4 ...

Page 126: ...12 50 BL PDSR 30 0319 03 07 2019 Figure 12 23 Telescopic and Trimast Scissor Assembly DR_0016 ...

Page 127: ...LOCKWASHER Ø4 8 3 0000 000702 00 FLATWASHER Ø4 8 4 2415 640008 10 DUST CAP 2 5 0000 000012 00 OIL BOTTLE Ø8 2 6 0000 001048 00 ROUND NUT M30X1 5 2 7 0000 001049 00 LOCKWASHER M30 2 8 0000 001407 00 BEARING 4 9 2415 642100 10 EXTERNAL SCISSORS 2 10 0000 000762 00 CIRCLIP OF HOLE Ø62 4 11 2415 640007 10 INNER DUSTPROOF PLATE 2 12 2415 643100 1A INTERNAL SCISSORS 1 ...

Page 128: ...12 52 BL PDSR 30 0319 03 07 2019 Figure 12 24 Trimast Lift Cylinder DR_0017 ...

Page 129: ... 43 5 6 5 1 2 0000 000370 00 O RING 40 3 1 1 3 1220 420001 0B CAP 1 4 1220 420004 00 BEARING 39 35 24 1 5 2415 680001 10 05 PISTON ROD 1 Used for Lift Height 157 5a 2415 680001 10 07 PISTON ROD 1 Used for Lift Height 189 6 2125 410003 00 COLLAR 2 7 2415 650001 10 RING BACK UP 40 35 15 1 8 2415 680002 10 PISTON 1 9 0000 000132 00 ROD PACKING 30 40 6 1 10 2125 410005 3A CUSHION COLLAR 1 11 2415 6810...

Page 130: ...12 54 BL PDSR 30 0319 03 07 2019 Figure 12 25 Reach Cylinder DR_0018 ...

Page 131: ... WASHER M18 1 3 2415 647004 10 SMALL ROUND NUT M18X1 5 1 4 0000 000137 00 SEAL 25X33X4 8 1 5 2415 647005 10 O RING 55X2 4 1 6 2415 647006 10 SEAL 25X33X5 1 7 2415 647001 10 GUIDE SLEEVE 1 8 2415 647007 10 O RING 50X3 1 1 9 2415 647200 10 PISTON ROD 1 10 0000 001089 00 SEAL 50X60X6 2 11 2415 647002 10 RETAINING RING 60X55X10 1 12 2415 647100 10 LEFT REACH CYLINDER TUBE 1 12 2415 648100 10 RIGHT REA...

Page 132: ...12 56 BL PDSR 30 0319 03 07 2019 Figure 12 26 Tilt Cylinder DR_0019 ...

Page 133: ... KIT FOR TILT CYLINDER 1 Includes Pos 5 6 7 8 9 1 2415 646100 10 CYLINDER BODY 1 2 2415 646001 10 RETAINING RING 10X2 5 1 3 2415 646200 10 PISTON ROD 1 4 2415 646002 10 GUIDE SLEEVE 1 5 0000 000966 00 O RING 63X3 1 1 6 0000 000980 00 SEAL 32 1 7 0000 000699 00 SEAL 53X63X6 2 8 0000 000972 00 SEAL 40X32X5 1 9 0000 000971 00 O RING 37X3 1 1 ...

Page 134: ...12 58 BL PDSR 30 0319 03 07 2019 Figure 12 27 Trimast Free Lift Cylinder DR_0020 ...

Page 135: ...es Pos 1 2 7 1 0000 000045 00 RING WIPER 55 63 5 6 5 1 2 0000 000690 00 O RING 60 3 1 1 3 2130 420002 30 CAP 1 4 2130 420001 30 01 PISTON ROD 1 Used for Lift Height 157 4a 2130 420001 30 03 PISTON ROD 1 Used for Lift Height 189 5 2130 420003 30 RING BACK UP 70 65 20 1 6 0000 000698 00 SNAP RING 53 63 2 1 7 0000 000699 00 COLLAR 53 63 6 1 8 2130 421000 30 01 CYLINDER TUBE 1 Used for Lift Height 157...

Page 136: ...12 60 BL PDSR 30 0319 03 07 2019 Figure 12 28 Hydraulic Lines for Trimast Lift Cylinder DR_0021 ...

Page 137: ...NEASSEMBLY LEFT 1 4 2415 426000 10 BLOCK CROSS 1 5 0000 000151 00 SCREW M8 25 2 6 2415 422000 1A 01 HYDRAULIC LINE 1 Used for Lift Height 157 6a 2415 422000 1A 03 HYDRAULIC LINE 1 Used for Lift Height 189 7 2415 430400 1A 01 HOSE 1 Used for Lift Height 157 7a 2415 430400 1A 03 HOSE 1 Used for Lift Height 189 8 2415 423000 10 HYDRAULIC LINE 1 9 0000 000321 00 SCREW M8 20 1 10 2415 420400 10 HYDRAUL...

Page 138: ...12 62 BL PDSR 30 0319 03 07 2019 Figure 12 29 Hydraulic Lines for Trimast DR_0022 ...

Page 139: ...mber 325200482 for Lift Height 157 3b 2415 428000 10 04 HYDRAULIC LINE ASSEMBLY 1 Used up to serial number 325200481 for Lift Height 189 3c 2415 428000 1B 04 HYDRAULIC LINE ASSEMBLY 1 Used from serial number 325200482 for Lift Height 189 4 0000 000109 00 SCREW M8X16 2 5 0000 000159 00 LOCKWASHER Φ8 2 6 0000 000176 00 FLATWASHER Φ8 2 7 0000 000274 00 BOLT M6 25 1 8 0000 000056 00 LOCKWASHER Ø6 3 9 ...

Page 140: ...12 64 BL PDSR 30 0319 03 07 2019 Figure 12 30 Hydraulic Lines for Reach Assembly Telescopic and Trimast DR_0023 ...

Page 141: ...INDER 1 3 2415 425000 10 TILT CYLINDER HYDRAULIC LINE 2 4 2415 432000 10 HYDRAULIC LINE FROM A1 TO RIGHT CYLINDER 1 5 2415 434000 10 HYDRAULIC LINE FROM B1 TO RIGHT CYLINDER 1 6 2415 431000 30 FLOWLINE A2 4 7 2415 432000 30 SIDESHIFTER HOSE 2 8 2415 437000 10 REVERSE HOSE 1 9 2415 436000 10 FORWARD HOSE 1 10 2702 141400 00 CONNECTOR G1 4 M14 1 5 5 11 0000 000044 00 WASHER Ø14 15 12 2401 143500 00 ...

Page 142: ...12 66 BL PDSR 30 0319 03 07 2019 Figure 12 31 Side Shift Assembly DR_0024 ...

Page 143: ... 4 3 0000 000373 00 FLATWASHER Ø12 4 4 2415 640100 00 01 LOAD BACKREST 1 28 Height 4a 2415 640100 00 02 LOAD BACKREST 1 36 Height 4b 2415 640100 00 03 LOAD BACKREST 1 48 Height 5 2415 645000 00 SIDE SHIFTER 1 6 3218 800001 10 FORK 2 Fork Length 36 6a 3218 800001 20 FORK 2 Fork Length 42 6b 3218 800001 40 FORK 2 Fork Length 48 7 3218 800002 00 PIN ASSEMBLY 2 ...

Page 144: ...12 68 BL PDSR 30 0319 03 07 2019 Figure 12 32 Side Shift Breakdown DR_0038 ...

Page 145: ...15 645111 00 PISTON ROD 1 6 0000 001566 00 BAFFEL 2 7 0000 000085 00 SEAL 2 8 0000 001567 00 BEARIN 2 9 2415 645500 00 WEAR PLATE 2 10 2415 645300 00 WEAR PLATE 2 11 2415 645100 0A SIDE SHIFT FRAME FIXED 1 12 0000 000587 00 LUBRICATION FITTING M6 4 13 2415 645200 00 SIDE SHIFT CARRIAGE MOVEABLE 1 14 2415 645400 30 LOCKING BLOCK 2 15 0000 000191 00 WASHER 4 16 0000 000220 00 WASHER 4 17 0000 001180...

Page 146: ...12 70 BL PDSR 30 0319 03 07 2019 Figure 12 33 Drag Chain Assembly I Trimast Free Lift Cylinder DR_0025 ...

Page 147: ...FT CYLINDER Pos Part Number Description Qty Reqd Notes 1 2415 600300 10 01 DRAG CHAIN I 1 Used for 157 Lift Height 1a 2415 600300 10 03 DRAG CHAIN I 1 Used for 189 Lift Height 2 0000 001243 00 SCREW M3X6 4 3 0000 000995 00 LOCKWASHER Ø3 4 4 0000 000999 00 FLATWASHER Ø3 4 ...

Page 148: ...12 72 BL PDSR 30 0319 03 07 2019 Figure 12 34 Drag Chain Assembly II Trimast Lift Cylinder DR_0026 ...

Page 149: ...CYLINDER Pos Part Number Description Qty Reqd Notes 1 2415 600400 10 01 DRAG CHAIN II 1 Used for 157 Lift Height 1a 2415 600400 10 03 DRAG CHAIN II 1 Used for 189 Lift Height 2 0000 001243 00 SCREW M3X6 4 3 0000 000995 00 LOCKWASHER Ø3 4 4 0000 000999 00 FLATWASHER Ø3 4 ...

Page 150: ...12 74 BL PDSR 30 0319 03 07 2019 Figure 12 35 Chain Assembly DR_0027 ...

Page 151: ...ht 102 5a 2415 600100 0A 03 CHAIN ASSEMBLY 1 Used for Lift Height 106 5b 2415 600100 00 02 CHAIN ASSEMBLY 1 Used for Lift Height 126 5c 2415 600100 10 01 CHAIN ASSEMBLY I 1 Used for Lift Height 157 5d 2415 600200 10 01 CHAIN ASSEMBLY II 1 Used for Lift Height 157 5e 2415 600100 10 03 CHAIN ASSEMBLY I 1 Used for Lift Height 189 5f 2415 600200 10 03 CHAIN ASSEMBLY II 1 Used for Lift Height 189 6 212...

Page 152: ...12 76 BL PDSR 30 0319 03 07 2019 Figure 12 36 Telescopic System Assemblies DR_0028 ...

Page 153: ...15 612000 10 ROLLER ASSEMBLY 6 5 2415 640004 10 SELF LUBRICATING BEARING 2 6 2415 640400 10 SLIDING PIN 2 7 0000 000277 00 BOLT M8X25 2 8 0000 000159 00 LOCKWASHER Ø8 2 9 0000 000176 00 FLATWASHER Ø8 2 10 2415 640012 10 01 WASHER A R As Required 2mm 10a 2415 640012 10 02 WASHER A R As Required 3mm 11 2415 612001 10 Screw 4 12 2415 612002 10 Snap Ring 4 13 2415 612003 10 Assistant Roller 4 14 2415 ...

Page 154: ...12 78 BL PDSR 30 0319 03 07 2019 Figure 12 37 Telescopic Mast Assembly DR_0029 ...

Page 155: ...Used for Lift Height 106 3b 2415 650000 00 02 LIFT CYLINDER 2 Used for Lift Height 126 4 2415 600007 10 CYLINDER BRACKET 2 5 0000 000255 00 BOLT M8X20 6 6 0000 000159 00 LOCKWASHER Ø8 14 7 0000 000176 00 FLATWASHER Ø8 14 8 0000 000251 00 BOLT M10X25 2 9 0000 000063 00 LOCKWASHER Ø10 2 10 0000 000175 00 FLATWASHER Ø10 2 11 2214 600001 00 CHAIN ROLLER 2 12 0000 000191 00 LOCKWASHER Ø16 2 13 0000 000...

Page 156: ...12 80 BL PDSR 30 0319 03 07 2019 Figure 12 37 Telescopic Mast Assembly Continued DR_0029 ...

Page 157: ...CKET 1 40 2125 500003 00 PROXIMITY SWITCH 8108 2 41 0000 000117 00 SCREW M5X10 6 42 0000 000206 00 LOCKWASHER Ø5 6 43 0000 000390 00 FLATWASHER Ø5 6 44 2415 520007 00 01 LIFT LIMIT PROXIMITY SWITCH WIRING 1 Used for Lift Height 102 44a 2415 520007 0B 03 LIFT LIMIT PROXIMITY SWITCH WIRING 1 Used for Lift Height 106 44b 2415 520007 00 02 LIFT LIMIT PROXIMITY SWITCH WIRING 1 Used for Lift Height 126 ...

Page 158: ...12 82 BL PDSR 30 0319 03 07 2019 Figure 12 38 Telescopic Reach Assembly DR_0030 ...

Page 159: ...1 10 EXTERNAL SCISSORS MAIN ROLLER 2 18 2415 642202 10 SLIDER 2 19 2415 642203 10 RETAINER RING Ø55 3 20 2415 642204 10 SCREW M10X1X12 2 21 2415 642205 10 SCREW M10X1X16 2 22 2415 643201 10 INTERNAL SCISSORS MAIN ROLLER 2 23 2415 643202 10 SLIDER 2 24 2415 643203 10 RETAINER RING Ø34 2 25 2415 643204 10 SCREW M10X1X14 2 26 2415 643205 10 SCREW M10X1X16 2 27 2415 640300 10 SHORT PIN WELDING 2 28 24...

Page 160: ...12 84 BL PDSR 30 0319 03 07 2019 Figure 12 38 Telescopic Reach Assembly Continued DR_0030 ...

Page 161: ...KWASHER Ø4 3 43 0000 000089 00 FLATWASHER Ø4 3 44 2415 640010 1A WASHER 2 45 2415 640011 10 WASHER 4 46 2415 640001 00 TUBING BAFFLE 1 Used from serial number 324200106 47 0000 000055 00 SCREW M6X16 2 Used from serial number 324200106 48 3316 610001 10 FIXED BLOCK 2 Used from serial number 324200106 49 0000 000988 00 BOLT M6X30 2 Used from serial number 324200106 ...

Page 162: ...12 86 BL PDSR 30 0319 03 07 2019 Figure 12 39 Telescopic Lift Cylinder DR_0031 ...

Page 163: ...ight 106 1b 2415 650001 20 02 PISTON ROD 1 Used for Lift Height 126 2 0000 000084 00 RING WIPER 35 43 5 6 5 1 3 2415 650003 10 CAP 1 4 2415 650002 00 BEARING 39 35 2 1 5 2415 651000 20 01 CYLINDER TUBE 1 Used for Lift Height 102 5a 2415 651000 20 03 CYLINDER TUBE 1 Used for Lift Height 102 5b 2415 651000 20 02 CYLINDER TUBE 1 Used for Lift Height 126 6 2415 650002 10 PISTON 1 7 2125 410003 00 COLL...

Page 164: ...12 88 BL PDSR 30 0319 03 07 2019 Figure 12 40 Hydraulic Lines for Telescopic Lift Cylinder DR_0032 ...

Page 165: ...IFT CYLINDER Pos Part Number Description Qty Reqd Notes 1 0000 000069 00 WASHER Ø16 3 2 2701 161600 00 CONNECTOR M16 1 5 M16 1 5 2 3 2415 423000 00 HYDRAULIC LINE ASSEMBLY 2 4 2415 426000 10 BLOCK CROSS 1 5 2401 161300 00 PLUG M16 1 5 1 6 0000 000169 00 SCREW M8 30 2 ...

Page 166: ...12 90 BL PDSR 30 0319 03 07 2019 Figure 12 41 Hydraulic Lines for Telescopic Mast DR_0033 ...

Page 167: ... Lift Height 106 3b 2415 424000 00 02 OIL PIPE 2 Used for Lift Height 126 4 2415 422000 00 01 HYDRAULIC LINE ASSEMBLY 1 Used for Lift Height 102 4a 2415 422000 0A 03 HYDRAULIC LINE ASSEMBLY 1 Used for Lift Height 106 4b 2415 422000 00 02 HYDRAULIC LINE ASSEMBLY 1 Used for Lift Height 126 5 2415 429000 10 BLOCK CROSS 1 6 0000 000032 00 SCREW M6X20 2 7 0000 000056 00 LOCKWASHER Ø6 2 8 2415 600002 10...

Page 168: ...12 92 BL PDSR 30 0319 03 07 2019 Figure 12 42 Telescopic Drag Chain Assembly DR_0034 ...

Page 169: ...ion Qty Reqd Notes 1 2415 600200 00 01 DRAG CHAIN 1 Used for Lift Height 102 1a 2415 600200 0A 03 DRAG CHAIN 1 Used for Lift Height 106 1b 2415 600200 00 02 DRAG CHAIN 1 Used for Lift Height 126 2 0000 001243 00 SCREW M3X6 4 3 0000 000995 00 LOCKWASHER Ø3 4 4 0000 000999 00 FLATWASHER Ø3 4 ...

Page 170: ...12 94 BL PDSR 30 0319 03 07 2019 Figure 12 43 Windshield DR_0035 ...

Page 171: ...ed from serial number 325200482 Lift Height 106 5c 2415 600007 0B 03 WINDSHIELD 1 Used up to serial number 325200481 Lift Height 126 5d 2415 600007 0C 03 WINDSHIELD 1 Used from serial number 325200482 Lift Height 126 5e 2415 600007 0B 04 WINDSHIELD 1 Used up to serial number 325200481 Lift Height 157 5f 2415 600020 1A 01 WINDSHIELD 1 Used from serial number 325200482 Lift Height 157 5g 2415 600020...

Page 172: ...Big Lift LLC ...

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