Big Lift Big Joe PDC Series Operation, Maintenance, Repair Parts List Download

Page: 127 / 198

902997

12-23

INDEX

NO.

PART

NO.



PART NAME

NO.

REQD.

077076

FLAT WASHER, 1-1/2 X 13/32 X 7

077211

SPLIT LOCK WASHER, 3/8

064605

HEX HEAD CAP SCREW,



HEAT TREATED

059429

HEX NUT, 3/8-16

101072

CYLINDER CLAMP

—

NOT USED

—

506654

ROLLER ASSEMBLY

405129

. ROLLER

051145

. BEARING

053012

THRUST WASHER, 3/32 THK.

A/R

053013

THRUST WASHER, 1/8 THK.

A/R

053014

THRUST WASHER, 5/32 THK.

A/R

053015

THRUST WASHER, 3/16 THK.

A/R

064607

HEX HEAD CAP SCREW,



3/8-16 X 1-1/4

—

500167

ROLLER ASSEMBLY

11A

051145

. BEARING

11B

401046

. ROLLER

025712

GREASE FITTING

239520

CLAMP BAR

060402

COTTER OIN, 1/16 X 3/8

402055

CLEVIS PIN, 0.200 DIA. X 1

069483

FLAT HEAD SCREW

191089

STOP BLOCK

077209

LOCK WASHER, 1/4

059421

HEX NUT, 1/4-20

100016

SPACER

064711

SCREW, HEX HEAD,



1/2-13 X 1-3/4

077213

LOCK WASHER, 1/2

—

505806

RAM HEAD ASSY

505805

. RAM HEAD

051120

. BEARING

074251

. SHEAVE

077022

. FLAT WASHER

061728

. RETAINING RING

402051

ADJUSTING BOLT

059545

JAM NUT, 5/8-18

077215

LOCKWASHER, 5/8

059445

HEX NUT, 5/8-18

402034

LIFT CHAIN



LIFT HEIGHT 106 IN.,



CHAIN LENGTH 6.21 FT



LIFT HEIGHT 130 IN.,



CHAIN LENGTH 8.38 FT



LIFT HEIGHT 154 IN.,



CHAIN LENGTH 10.42 FT



LIFT HEIGHT 168 IN.,



CHAIN LENGTH 11.52 FT

VAR

OUTER MAST

VAR

INNER MAST

—

LIFT CYLINDER (

FIGURE 12-33

)

REF

236001

SPINDLE

074810

SPINDLE

402322

SWITCH PLATE

063478

HEX HEAD CAP SCREW,



1/4-20 X 3/4

077209

LOCK WASHER, 1/4

020703

HIGH SPEED CUTOFF SWITCH

A/R - AS REQUIRED

INDEX

NO.

PART

NO.



PART NAME

NO.

REQD.

Summary of Contents for Big Joe PDC Series

Page 1: ...Big Lift LLC MANUAL NO 902997 www bigjoeforklifts com 02 05 2014 PDC SERIES POWER DRIVEN COUNTERBALANCED LIFT TRUCK Serial Number 384041 and Higher Operation Maintenance Repair Parts List ...

Page 2: ......

Page 3: ...8 1 8 2 LIFT CHAIN ADJUSTMENT NON TELESCOPIC AND TELESCOPIC 8 1 8 3 LIFT CHAIN ADJUSTMENT FULL FREE LIFT 8 2 8 4 LIFT CHAIN ADJUSTMENT CLEAR VIEW TRIMAST 8 3 8 4 1 FULL FREE LIFT CHAIN 8 3 8 4 2 SECONDARY LIFT CHAINS 8 3 8 5 LIFT CHAIN INSPECTION 8 4 8 6 LIFT CHAIN REPLACEMENT NON TELESCOPIC AND TELESCOPIC 8 4 8 7 LIFT CHAIN REPLACEMENT FULL FREE LIFT 8 4 8 8 LIFT CHAIN REPLACEMENT CLEAR VIEW TRIM...

Page 4: ...YDRAULIC SYSTEM CLEAR VIEW TRIMAST 9 6 9 6 HYDRAULIC SYSTEM 9 8 9 7 HYDRAULIC PANEL ASSEMBLY 9 10 9 8 PUMP AND MOTOR 9 11 9 9 STANDARD CONTROL VALVE 9 12 9 10 LIFT CYLINDER NON TELESCOPIC AND TELESCOPIC 9 14 9 11 LIFT CYLINDER ASSEMBLY FULL FREE LIFT 9 15 9 12 TILT CYLINDER 9 16 9 13 TILT CYLINDER 9 17 9 14 TILT CYLINDER 9 18 10 1 CONTROL PANEL ASSEMBLY TYPE E 10 2 10 2 CONTROL PANEL ASSEMBLY TYPE...

Page 5: ...NEL ASSEMBLY TYPE E 12 80 12 46 CONTROL PANEL ASSEMBLY TYPE EE 12 82 12 47 CONTACTOR FORWARD REVERSE 12 84 12 48 DEAD MAN BRAKE SWITCH 12 85 12 49 REMOTE CONTROL OPTION 12 86 12 50 OPTIONAL HOUR METER SWITCH INSTALLATION 12 88 12 51 BATTERY CAPACITY INDICATOR WIRING DIAGRAMSYSTEMS WITHOUT LOCKOUT 12 90 12 52 BATTERY CAPACITY INDICATOR WIRING DIAGRAM SYSTEMS WITH LOCKOUT 12 91 12 53 OPTIONAL KEY SW...

Page 6: ...iv 902997 NOTES ...

Page 7: ...902997 1 ...

Page 8: ...1 2 902997 ...

Page 9: ...902997 1 ...

Page 10: ...1 2 902997 ...

Page 11: ...inst load backrest Do not handle unstable or loosely stacked loads Use special care when handling long high or wide loads to avoid losing the load striking bystanders or tipping the truck Do not handle loads which are higher than the load backrest or load backrest extension unless load is secured so that no part of it could fall backward Elevate forks or other lifting mechanism only to pick up or ...

Page 12: ...vi 902997 NOTES ...

Page 13: ...payloads on adjustable forks that can be tilted up and down The PDC 15 can lift up to 1500 pounds The PDC 20 can lift up to 2000 pounds The PDC 25 can lift up to 2500 pounds The PDC 30 can lift up to 3000 pounds The PDC 40 can lift up to 4000 pounds Figure 1 1 Name Plate The forward and reverse motion is controlled by a speed controller switch in the control head Stopping and turning is controlled...

Page 14: ...emote Lift Control Cold Conditioning Battery Capacity Meter Hour Meter Lift Limit Switch Lift Limit Override Switch Larger capacity batteries with corresponding battery chargers 1 5 SAFETY SYMBOLS WARNING This WARNING sign denotes a hazard It calls attention to a procedure practice or the like which if not correctly performed or adhered to could result in personal injury CAUTION This CAUTION sign ...

Page 15: ...902997 1 3 Figure 1 2 PDC Lift Truck R5378 LIFT CARRIAGE TILT CYLINDER LIFT CYLINDER MAST BASE AND FRAME ...

Page 16: ...1 4 902997 NOTES ...

Page 17: ...age to the hydraulic system and structural components 4 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 bystanders 5 Center and carry the load as far back as possible toward the lift carriage back rest Do not pick up loads on the tips of forks The center of gravity of the load must not exceed the load ...

Page 18: ...Check for signs of fluid leakage Forks Check for cracks and damage and that they are properly secured Chains cables and hoses Check that they are in place properly secured and not damaged or binding 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 ho...

Page 19: ...ist Date Big Joe Manufacturing Company Operator Truck No Model No Dept Check Tires Lights Horn Lift Lower Control Tilt Control Attachment Operation Drive Control Steering Service Brakes Parking Brake Hydraulic Leaks Cylinders Valves Hoses Etc Need Maintenance O K Shift Hour Meter Reading Drive Hoist ...

Page 20: ...les on some models have pushbuttons for raising and lower ing the forks Table 2 2 lists optional control handles Control handles on all models have a belly button reversing switch which reverses the direction of the truck upon contact with the operator Table 2 2 Control Handles Figure 2 3 Control Handle Type Part Numbers Standard 505360 01 Remote Lift in Handle 505360 02 Remote Lift and Lower in H...

Page 21: ...to the truck preventing unauthorized personnel from operat ing the machine Some models have additional control levers for the operation of additional accessories 2 5 OPERATION 2 5 1 Forward and Reverse Travel and Speed Control All directional and speed controls are located on the control handle See Figure 2 3 Forward and reverse are controlled by rotating the speed control lever as shown The lever...

Page 22: ...ke disc Further vertical positioning increases the braking force and de energizes the controls This position serves as a parking brake As a safety precaution the steering arm is spring loaded to return to the vertical position in the event the driver releases the control handle during operation This is known as deadman brak ing 4 Dynamic Brake The dynamic brake serves as a secondary braking system...

Page 23: ...ruck by the control handle with the load trailing except when in confined areas Ramps should be traveled with operator uphill of truck when empty or operator downhill of truck when load on forks 9 Always look in the direction of travel Move slowly and check clearances when approaching obstruc tions 10 Do not make sudden starts and stops Operate truck smoothly and gradually 11 Travel slowly and squ...

Page 24: ...2 8 901349 NOTES ...

Page 25: ...tery to become completely dis charged specific gravity 1 150 or less This will also greatly shorten battery life 3 3 2 Battery Servicing Refer to Document 245 for battery safety and maintenance The battery cells are accessed by opening the top cover of the battery Use the following procedure 1 Obtain a battery hydrometer NOTE These can be obtained from a local hardware store or automotive shop 2 U...

Page 26: ...iller neck 3 4 LUBRICATION Refer to Table 3 2 for the recommended types of grease and oil and Table 3 3 for hydraulic oil capaci ties Table 3 4 in conjunction with Figure 3 1 identifies the items requiring lubrication Table 3 2 Recommended Lubricants and Oils Table 3 3 Hydraulic Oil Capacity Chart No 1 Transmission oil EP SAE 80W 90 Transmission oil EP SAE 10W 30 Note Transmission oil capacity is ...

Page 27: ...Gun No 2 Pressure lubricate 2 Tilt cylinder mounts Gun No 2 Pressure lubricate both ends of each cylinder 3 Outer and inner masts Brush No 2 Full length of mast where rollers touch 4 Free lift slide bar Telescopic Trucks Brush No 2 Full length of slide bar where ram head touches 5 Chain sheaves Gun No 2 Pressure lubricate 6 Transmission Can No 1 Fill to plug level R5380 3 4 5 6 2 1 ...

Page 28: ...3 4 902997 NOTES ...

Page 29: ...battery quick disconnect plug Check battery See SEC TION 3 c Defective keyswitch Check and replace if required e Defective wiring Check for open circuit Repair as required TROUBLE WITH TRAVEL Check all wiring A loose connec tion may be the cause of mal function Tighten all loose connections before further troubleshooting Truck does not run forward or reverse Everything else is nor mal a 15 Amp con...

Page 30: ...NG OR LOWERING Oil level too low Check hydraulic oil level Fill hydraulic reservoir so that oil is shown full on dipstick approxi mately 2 inches from top of res ervoir with lift carriage fully lowered before further trouble shooting Tighten all electrical connections Lift carriage does not rise everything else is normal a Defect in electrical system a If pump motor does not run when LIFT control ...

Page 31: ...oir b Dry channels in mast Apply grease c Defective bearing Replace bearing Forks does not lift to top Pump motor runs a Oil level too low Add oil to reservoir b Load heavier than capacity Refer to nameplate for maximum load capacity c Defective pump or motor Replace Oil leaks at control valve spools Defective O rings on valve spools Replace O rings or replace valve Control valve spring centered h...

Page 32: ...rm is pulled down a Belly button reversing switch defective Check for short and repair or replace as necessary b Forward contactor stuck closed Repair or replace Steering arm jerks excessively when starting or stopping the truck a Worn pivot tube bushings Replace upper and lower pivot tube bushings b Drive tire worn or mounted incorrectly Repair or replace ...

Page 33: ...902997 4 5 NOTES ...

Page 34: ...ROL S2 S1 2 OPTIONAL CIRCUITS DASHED X DENOTES CONNECTION BROKEN WITH OPTIONAL CIRCUIT DI DISCHARGE INDICATOR OPT HM HOUR METER OPT L REMOTE LOWERING OPT P PUMP SOLENOID R REVERSE CONTACTOR F FORWARD CONTACTOR 1 SYMBOLS NOTES 2 KEYSWITCH 15 A BATTERY DI MOTOR PUMP P A2 A1 ARMATURE DRIVE MOTOR FIELD DRIVE MOTOR F F R R 300 A P v LIFT TILT 3 SPOOL LIFT LIMIT OVERRIDE 2 4 SPOOL RS REMOTE LIFT OPT PDC...

Page 35: ...GE INDICATOR OPT HM HOUR METER OPT L REMOTE LOWERING OPT P PUMP SOLENOID R REVERSE CONTACTOR F FORWARD CONTACTOR 1 SYMBOLS NOTES CONTROL HEAD REVERSING DEADMAN REMOTE HORN HM L HORN FL POTENTIOMETER 5K SPEED CONTROL COLD CONDITIONING LOWER LIFT REMOTE F R LIMIT SWITCH TRAVEL SPEED 2 7K RS REMOTE LIFT OPT RS F R v v v PDC 15 PDC 20 PDC 25 PDC 30 TYPE E EE R7077B ...

Page 36: ...4 8 902997 Figure 4 2 Electrical Schematic Sheet 1 R7078A PDC 40 TYPE E EE ...

Page 37: ...902997 4 9 Figure 4 2 Electrical Schematic Sheet 2 R7078B PDC 40 TYPE E EE ...

Page 38: ...LIFT LIMIT SWITCH OVERRIDE 11 15 S2 S1 KEYSWITCH SOLID STATE CONTROL AND CONTACTOR PANEL 3 10 4 1 2 3 3 3 8 7 A1 10 10 12 15 TRAVEL SPEED LIMIT SWITCH 8 8 8 13 14 13 14 TERMINAL BOARD ON TRANS LIFT LOCKOUT 18 10 10 LOWERING SOLENOID REMOTE REMOTE SOLENOID LIFT TILT 8 9 NON TEL TEL MAST SWITCH ON C V TRI C V FFL TO 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 NC NO C NOTES 1 DASHED CIRCUITS ARE OPTIONAL ...

Page 39: ...TS ARE OPTIONAL ITEMS 2 BREAK FOR OPTIONAL ITEMS 9 18 8 10 3 3 8 8 8 TERMINAL BOARD ON TRANS 6 6 13 NO MAIN CONNECTOR TRANS CNCTRL REPLACES STD 21 T S LIMIT SW 2nd 1st NEG RED CONTCTR PANEL WIRE 15 TO BLACK CONTCTR PANEL WIRE 12 TO YELLOW 22 POS SOLENOID ORANGE BLUE VLV N C STAGE VLV N O STAGE 5 COND CABLE VALVES C V FFL C V TRI SW LIMIT SWITCH TRAVEL SPEED NC NO SWITCH LIFT CYL NC MAST 23 MAST ST...

Page 40: ...R 2 1 8 DIODE ASSY HOUR METER LIFT LIMIT SWITCH OVER RIDE 11 15 S2 S1 KEYSWITCH SOLID STATE CONTROL AND CONTACTOR PANEL NOTES 1 DASHED CIRCUITS ARE OPTIONAL ITEMS 2 X BREAK FOR OPTIONAL ITEMS 3 SEE ELECTRICAL SCHEMATIC 505896 3 10 4 1 2 3 3 3 8 7 A1 10 10 12 15 8 13 14 13 14 TERMINAL BOARD ON TRANS LIFT LOCKOUT 10 10 13 14 10 3 9 REMOTE LIFT SOLENOID REMOTE LOWERING SOLENOID 8 8 8 TILT 18 8 LIFT V...

Page 41: ...IN CONNECTOR CONTCTR PANEL POS WIRE TO NEG 22 RED POS 24 BLUE WIRE 15 TO CONTCTR PANEL TRANS CNCTRL 21 BLACK 21 C 22 NO NC POS C NO NC MAST SW CLEAR VIEW TRIMAST MAST STAGING VALVES SWITCHES CIRCUIT N C VLV 2nd STAGE 5 COND CABLE SOLENOID VALVES 23 N O VLV 1st STAGE CONTROL HEAD FWD REV 4 REVERSING 3 10 3 1 2 6 4 5 9 8 7 16 13 1112 1415 10 3 13 5 24V COLD CONDITIONING 9 LOWER 12 1 2 3 3 6 11 7 8 L...

Page 42: ...4 14 902997 Figure 4 5 Wiring Diagram Sheet 1 R7079A PDC 40 TYPE E ...

Page 43: ...902997 4 15 Figure 4 5 Wiring Diagram Sheet 2 R7079B PDC 40 TYPE E ...

Page 44: ...4 16 902997 Figure 4 6 Wiring Diagram Sheet 1 PDC 40 TYPE EE R7080A ...

Page 45: ...902997 4 17 Figure 4 6 Wiring Diagram Sheet 2 PDC 40 TYPE EE R7080 ...

Page 46: ...4 18 902997 NOTES ...

Page 47: ...e per formance in cold temperatures Heating resistors are provided for the control head switches and cold resis tant versions of other switches are used Special cold temperature lubricants are also necessary for this application Figure 5 1 is an electrical schematic diagram of the cold conditioning circuit Location of electrical parts in the control head and resistor wiring of cold condition ing e...

Page 48: ...ard near the end of travel the switch could be unreliable and may not actuate in some instances 6 Repeat steps 2 through 5 until pressing the belly button casting actuates the switch properly 7 Reconnect battery and electrical connections WARNING Testing of belly button switch in opera tion should be limited to areas clear of obstacles against which an operator could be pinned Use low speed revers...

Page 49: ...fore disconnecting 1 Disconnect battery 2 If necessary to gain access to defective belly but ton switch remove belly button casting 54 Fig ure 5 5 by performing step 2 in paragraph 5 3 3 Remove top cover 13 14 or 15 Figure 5 6 by removing four screws 12 4 Remove switch plate 16 by removing four screws 22 and 23 Figure 5 5 on top and bottom of control handle 53 5 Replace belly button switches 5 dir...

Page 50: ...5 4 902997 Figure 5 5 Control Head Assembly R6089 SEE Figure 5 6 FOR SWITCHS SEE Figure 12 3 FOR COLD CONDITIONING ...

Page 51: ...hed 9 Remove roll pin 16 from right hand handle grip 41 10 Remove right hand handle grip from shaft 38 11 Remove set screw 30 from right hand control lever 52 12 Remove right hand control lever from tube 45 13 Observing through top cover opening slide shaft 38 with tube 45 out left hand side of control head just enough to clear return spring 32 14 Disengage return spring from spiral pin 18 and rem...

Page 52: ...ers grip the flat surfaces of the spring tube assembly 4 and rotate clock wise 180 degrees 5 Hold spring tube assembly in rotated position and tighten screw 1 to secure 6 Check the spring action by lowering the steering arm and returning it to the upright position two or three times 7 If necessary repeat steps 2 through 6 increas ing or decreasing amount of rotation of the spring tube assembly unt...

Page 53: ...til the steering arm return spring snaps into place over spring pins 14 and 15 then tighten screw 1 12 Apply engine lubricating oil No 2 to the steering arm elbow 13 Remove block from under steering arm 14 Adjust tension on steering arm return spring as explained in paragraph 5 7 15 Reconnect battery 5 9 PIVOT TUBE REPLACEMENT NOTE All electrical connections and cabling should be tagged with ident...

Page 54: ... Remove hoist chain and the two pivot cap cover screws or pivot tube tool as applicable 20 Install bushing 3 and secure with three screws 2 21 Install spacer 1 on pivot tube 7 CAUTION Be sure to observe cable routing and positioning when reinstalling electrical control cable to prevent cable damage 22 Reinstall steering arm onto pivot tube being care ful not to damage electrical control cable whil...

Page 55: ...brake linkage The wire connected to pin number 3 on the terminal board 9 is a wire that comes from R5150 12 11 13 7 10 8 9 4 5 6 1 2 3 R962 R963 1 CABLE CLAMP 2 CABLE CLAMP 3 SPRING TUBE ASSEMBLY 4 ELECTRICAL CONTROL CABLE 5 PIVOT CAP 6 PIVOT CAP COVER 7 CAP SCREWS 8 FEMALE CONNECTOR 9 TERMINAL BOARD 10 PIVOT TUBE 11 TRANSMISSION HOUSING ...

Page 56: ...ble under spring tube assembly 3 and out the opening at the elbow 15 Eliminate cable slack in pivot tube 10 then secure cable with cable clamp 1 CAUTION Improper cable loop adjustment while performing the following step will dam age the cable If too tight the cable will tear when the steering arm is in the up position If too loose the cable will buckle or be pinched when the steering arm is in the...

Page 57: ...ly shaded area in Figure 6 1 proceed as follows 1 Disconnect battery connections 2 Securely block the truck to prevent slipping then jack up the truck so the drive wheel is off the ground 3 Remove base access cover 4 Secure steering arm assembly in a position that is in either lightly shaded area shown in Figure 6 1 Figure 6 1 Brake Engage Disengage R3629 ...

Page 58: ...witch to the mounting bracket then sliding the switch in or out in the adjustment slots and tightening the screws 17 Make sure that applying the brake activates the switch but does not fully depress the switch plunger If necessary repeat steps 15 and 16 until the switch is properly positioned 18 Lower the truck and install the base access cover 19 Reconnect battery connections 20 In an area free o...

Page 59: ... weldment 17 and hold them so the bolt holes are aligned 14 Insert the bolts 30 through pad 37 and bracket 17 so the threaded portion of the bolts passes completely through 15 Assemble the two lock washers 29 and nuts 28 to the bolts 30 16 Engage the clevis 13 with the lever 39 then insert the pin 7 and secure it with the cotter pin 2 17 Remove the restrictions from the steering arm 18 Adjust the ...

Page 60: ... assembly 27 then remove the assembly 8 Remove the nut 21 and lock washer 20 9 Remove the disc assembly 19 10 Remove the key 18 11 Install new disc assembly with key 18 lock washer 20 and nut 21 12 Assemble the brake pad 33 springs 32 and spacers 31 to the two bolts 30 13 Slip brake pad 37 with attached parts onto the mounting plate weldment 17 and hold it so the bolt holes are aligned 14 Insert t...

Page 61: ...otor 38 are properly labeled A1 A2 F1 and F2 and then disconnect the cable from the drive motor 7 Disconnect the mechanical brake by removing cotter pin 1 Figure 7 2 clevis pin 2 that secures the rod clevis to the lower lever assembly 3 NOTE Transmission oil capacity is 3 pints 8 Remove the transmission drain plug 5 Figure 7 1 and drain the transmission oil 9 Position the drive assembly to access ...

Page 62: ...14 and pinion spacer 13 18 Remove intermediate gear 12 and square key 10 19 Remove spur pinion 11 20 Remove locknut 8 and lock washer 7 21 Remove drive wheel and axle shaft 1 to free gear 6 roller bearing cones 3 and cups 4 and oil seal 2 22 Remove ball bearing 9 23 Refer to the disassembly instruction as a guide and reverse the individual procedures of steps 22 through 1 to reassemble and reinsta...

Page 63: ...orting boards or steel bars under the body so that when the front end is lowered it will remain about 6 inches off the floor and the load wheel will not touch the floor 5 Lower the lift truck onto the support 6 Remove dust cap 10 Figure 7 3 7 Remove nut 9 and washer 8 8 Slide load wheel hub 4 off of spindle 9 Remove grease seal 1 and bearings 2 and 7 10 Clean and check bearings and grease seal for...

Page 64: ...7 4 902997 NOTES ...

Page 65: ...lly lower lift carriage 2 Disconnect the battery 3 Loosen nut 29 on chain adjusting bolt 28 on the lift carriage 4 Take up slack by tightening nut 31 CAUTION At least 3 full threads must be present below hex nut after completion of adjust ment 5 Secure adjustment by tightening nut 29 against the lift carriage Figure 8 1 Elevation System 6 Reconnect battery PDC 20A PDC 20 PDC 25 PDC 30 TELESCOPIC L...

Page 66: ...djusting bolt 20 on the lift carriage 4 Take up slack by tightening nut 23 CAUTION At least 3 full threads must be present below hex nut after completion of adjust ment 5 Secure adjustment by tightening nut 21 against the lift carriage 6 Reconnect battery 7 Test chain by operating carriage If slack is still apparent repeat above procedure Figure 8 2 Elevation System PDC 20A PDC 20 PDC 25 PDC 30 FU...

Page 67: ...y Lift Chains 36 Figure 8 3 WARNING Before attempting any adjustment make certain power is disconnected 1 Fully lower the lift carriage 2 Disconnect the battery 3 Loosen nut 5 on chain adjusting bolt 28 on upper cross member of outer mast 31 4 Take up the slack by tightening nut 3 CAUTION At least 3 full threads must be present below hex nut after completion of adjust ment 5 Secure adjustment by t...

Page 68: ...nect end of chain to mast cross brace with new clevis pin 15 9 Adjust chain according to paragraph 8 2 8 7 LIFT CHAIN REPLACEMENT FULL FREE LIFT 1 Place a solid block on floor under the vertical members nearest the center of the lift carriage 2 Lower lift carriage until it is supported by the block and the load chains are slack then disconnect battery WARNING Before attempting any actual replace m...

Page 69: ... ram head 23 11 Remove lift cylinder clamp 5 CAUTION Hold lift cylinder securely during the final stages of this procedure 12 Remove screw 3 and washers 1 and 2 from bottom of lift cylinder 13 Raise the lift cylinder up and out of the truck NOTE Disassembly of lift cylinder is covered in SEC TION 9 14 Reinstall lift cylinder in reverse order of removal 15 Adjust chain according to paragraph 8 2 8 ...

Page 70: ...ree tube from the secondary lift cylinder 34 4 Disconnect the tube connector regulator reducer and elbow from the bottom of the secondary lift cylinder 34 5 Remove screw and lock washer 11 from the bot tom of the secondary lift cylinder 6 Remove screw 25 and lock washer 26 from the top of the secondary lift cylinder WARNING Lift cylinder must be supported during the next step 7 Support lift cylind...

Page 71: ...902997 8 7 Figure 8 4 Hydraulic System PDC 20A PDC 20 PDC 25 PDC 30 SHOWN ALL OTHER NON TEL TEL FLL TRUCKS SIMILAR R2026M ...

Page 72: ...43 34 24 21 42 38 39 TO SPOOL VALVE 2 3 17 18 37 31 32 36 2 35 29 TO TILT CYLINDER 26 26 41 33 46 49 50 60 30 50 15 TO SPOOL VALVE 16 TO TANK RETURN 75 74 TO MAST SWITCH TO ELEC PANEL TO PUMP MTR NEG 76 74 36 2 10 A B C D 83 2 3 6 7 8 5 4 1 22 23 15 16 17 18 19 20 87 88 89 90 91 94 93 92 95 96 97 98 PDC 20 PDC 25 PDC 30 CLEAR VIEW TRIMAST SHOWN PDC 40 CLEAR VIEW TRIMAST TRUCKS SIMILAR ...

Page 73: ... SWITCH 63 62 27 29 51 28 48 47 53 53 SINGLE CYLINDER 64 72 CABLE ROUTING WIRE HOSE TIES PARTIAL VIEW H H PULL LOOPED HOSE AWAY FROM CABLE W WIRE TIE AROUND LIMIT SWITCH ANGLE IRON SECURE EXTRA CABLE TO ANGLE IRON WITH WIRE TIES 53 ANGLE IRON 72 77 ROUTE ITEM 77 CABEL THRU CYL RETAINING STRAP 53 TO STAGING VALVES 84 72 74 73 70 69 53 COVER CABLE W ELEC TAPE UNDER CLAMP 78 COVER CABLE W ELEC TAPE U...

Page 74: ...g on bolt 8 Pull tilt control to BACK position to free tilt cylinder from mast WARNING Before disconnecting any hydraulic lines make certain the system is not under pressure Refer to paragraph 9 1 9 Disconnect the hydraulic hoses form the lift cylinder 10 Remove external retainer rings 13 Figure 8 7 mast support shaft 12 standard washers 20 and round washers 21 11 Lift the masts from chassis frame...

Page 75: ...902997 8 11 Figure 8 6 Inner and Outer Masts Full Free Lift R1343M PDC 20A PDC 20 PDC 25 PDC 30 FULL FREE LIFT SHOWN PDC 40 FULL FREE LIFT SIMILAR ...

Page 76: ...8 12 902997 Figure 8 7 Base and Frame R1342M ...

Page 77: ...be remedied by simply tightening the fitting If this does not remedy the leak the fitting or line must be replaced A leak in the suction line between the pump and the reservoir will sometimes cause hydraulic oil to foam through the vent WARNING Before disconnecting any hydraulic lines make certain the system is not under pressure Refer to paragraph 9 1 1 Remove reservoir drain plug 21 Figure 9 7 a...

Page 78: ...9 2 902997 Figure 9 1 Hydraulic System Non Telescopic and Telescopic R2026M PDC 20A PDC 20 PDC 25 PDC 30 SEE SUPPLEMENT 269 FOR OPTIONAL AUXILIARY HYDRAULICS ...

Page 79: ...902997 9 3 Figure 9 2 Hydraulic System Non Telescopic and Telescopic R2027M PDC 40 SEE SUPPLEMENT 269 FOR OPTIONAL AUXILIARY HYDRAULICS ...

Page 80: ...9 4 902997 Figure 9 3 Hydraulic System FFL R2028M PDC 20 PDC 25 PDC 30 SEE SUPPLEMENT 269 FOR OPTIONAL AUXILIARY HYDRAULICS ...

Page 81: ...902997 9 5 Figure 9 4 Hydraulic System FFL R2029M PDC 40 SEE SUPPLEMENT 269 FOR OPTIONAL AUXILIARY HYDRAULICS ...

Page 82: ...D 11 14 12 13 24 8 9 24 25 45 44 43 34 24 21 42 38 39 TO SPOOL VALVE 2 3 17 18 37 31 32 36 2 35 29 TO TILT CYLINDER 26 26 41 33 46 49 50 60 30 50 15 TO SPOOL VALVE 16 TO TANK RETURN 75 74 TO MAST SWITCH TO ELEC PANEL TO PUMP MTR NEG 76 74 36 2 10 A B C D 83 2 3 6 7 8 5 4 1 22 23 15 16 17 18 19 20 87 88 89 90 91 94 93 92 95 96 97 98 PDC 20 PDC 25 PDC 30 ...

Page 83: ...TAIL CYLINDER SWITCH TRAVEL SPEED SWITCH 63 62 27 29 51 28 48 47 53 53 SINGLE CYLINDER 64 72 CABLE ROUTING WIRE HOSE TIES PARTIAL VIEW H H PULL LOOPED HOSE AWAY FROM CABLE W WIRE TIE AROUND LIMIT SWITCH ANGLE IRON SECURE EXTRA CABLE TO ANGLE IRON WITH WIRE TIES 53 ANGLE IRON 72 77 ROUTE ITEM 77 CABEL THRU CYL RETAINING STRAP 53 TO STAGING VALVES 84 72 74 73 70 69 53 COVER CABLE W ELEC TAPE UNDER C...

Page 84: ... 46 4 44 18 43 REG FLOW TO SPOOL VALVE 3 36 35 33 29 49 37 39 38 34 32 31 10 13 11 12 14 TO TILT CYLINDER 50 61 25 24 TO SPOOL VALVE 17 16 50 30 26 26 TO TILT FORWARD TO STAGING VALVE ASSY TO PUMP PRESSURE PORT TO TILT BACK 363 20 74 A B C D TO TANK 8 7 6 5 4 3 1 2 22 23 19 16 9 18 17 85 86 87 88 89 90 91 87 96 95 96 92 93 PDC 40 ...

Page 85: ...G DETAIL 72 79 80 77 81 82 TRAVEL SPEED LIMIT SWITCH 62 63 84 48 47 72 52 78 TO STAGING VALVES 53 53 28 COVER CABLE W ELEC TAPE UNDER CLAMP COVER CABLE W ELEC TAPE UNDER CLAMP PARTIAL VIEW H H CABLE ROUTING WIRE HOSE TIES 53 53 ROUTE ITEM 77 CABEL THRU CYL RETAINING STRAP SINGLE CYLINDER 77 72 53 PULL LOOPED HOSE AWAY FROM CABLE W WIRE TIE AROUND LIMIT SWITCH ANGLE IRON SECURE EXTRA CABLE TO ANGLE...

Page 86: ... suitable container 4 Remove filter 20 5 Install new filter 6 Clean the drain plug thoroughly 7 Reinstall the drain plug NOTE Refill only with Big Joe hydraulic oil and only while the lift carriage is completely lowered Refill until oil is to the FULL mark on the dip stick Refer to SECTION 3 for oil capacities 8 Remove the reservoir vent cap fill the reservoir to the FULL mark on the dip stick and...

Page 87: ...ock washers 3 to disassemble pump 2 from motor 1 7 If the pump is defective install a new pump If motor is defective a new motor may be installed or motor may be rebuilt see SECTION 10 8 Reinstall assembly in truck and connect hydraulic lines to pump and electrical wires to motor 9 Clean the drain plug thoroughly 10 Reinstall the drain plug NOTE Refill only with Big Joe hydraulic oil and only whil...

Page 88: ... disconnect the harness wires 16 Figure 9 9 from the switches 15 at the bottom of the control valve 5 Remove pivot pin 9 and spacer 7 that attach control levers 5 and 6 to truck body 6 Disconnect levers 5 and 6 from valve by remov ing clevis pins 13 7 Remove the control valve by removing the four screws 17 washers 11 and nuts 10 NOTE Refer to Figure 12 21 and Figure 12 22 for disassembly and reass...

Page 89: ...embly 12 at swivel connec tor from elbow 48 Remove elbow from control valve 4 Remove flow control valve 50 5 Remove reducers 49 from flow control valve 50 and install them in the new flow control valve 6 Install new flow control valve making certain direc tion of free flow as marked on valve is toward lift cylinder 7 Install elbow 48 and reconnect hose 12 8 Reconnect battery 9 Raise forks then rem...

Page 90: ... in vise 6 Remove nut 11 and pull off piston 14 and O ring 7 Remove PSP seal 15 from piston 14 NOTE Refer to Figure 12 33 Figure 12 35 or Figure 12 36 for the proper Packing Kit 7 Install new PSP seal 15 on piston 14 8 Install new O ring 7 piston 14 and nut 11 on cylinder ram 5 9 Remove cylinder ram 5 from vise CAUTION To prevent cylinder damage use proper pipe clamp vise The cylinder will be dis ...

Page 91: ...r ring 9 PSC seal 10 felt ring 16 and wear ring 9 from outside of primary rod 17 7 Unthread gland nut 18 from the bottom of the primary rod 17 8 Remove rod wiper 5 polypack 6 backup ring 7 and O ring 8 9 Slide secondary rod 19 out of the primary rod 17 10 Remove wear rings 13 from the outside of sec ondary rod 19 11 Unthread rod end 21 from the bottom of the pri mary rod 19 12 Remove O ring 11 and...

Page 92: ...igure 9 12 Unthread gland nut 12 from barrel 2 using spanner wrench and remove barrel 2 2 Unthread nut 3 3 Remove piston 5 o ring 4 and gland nut 12 from piston rod 8 4 Remove grease fittings 1 from barrel 6 and rod end 14 NOTE Before reassembling the hydraulic cylinder it is recommended that Packing kit items 4 6 7 9 11 and 13 be replaced 5 Reassemble the cylinder in reverse order of dis assembly...

Page 93: ...he vise 5 Remove nut 3 while holding piston rod 13 with a wrench on its flats 6 Remove piston 6 and head 9 from piston rod 13 7 Remove seal 4 from piston 6 8 Remove O ring 7 and backup ring 8 from the OD of head 9 9 Remove dust seal 11 and rod seal 10 from the ID of head 9 10 Remove grease zerks 1 from barrel 2 and rod end 14 NOTE Before reassembling the hydraulic cylinder it is recommended that p...

Page 94: ... 10 from jacket assembly 6 using spanner wrench and remove jacket assembly 6 2 Unthread locknut 1 3 Remove piston 3 o ring 4 spacer 5 and gland nut 10 from piston rod 7 4 Remove grease fittings 13 from jacket assembly 6 and rod end 12 NOTE Before reassembling the hydraulic cylinder it is recommended that Packing kit items 2 4 8 9 and 11 be replaced 5 Reassemble the cylinder in reverse order of dis...

Page 95: ...ng the battery 4 Make sure the connections to the bus bars are tight Use two well insulated wrenches for this task in order to avoid stressing the bus bars Table 10 1 Electrical Control Panels 10 1 2 Panel Removal 1 Disconnect the battery 2 Open the cabinet door 1 Figure 12 8 3 Refer to Figure 4 3 Figure 4 4 Figure 4 5 or Fig ure 4 6 and tag and disconnect all electrical wires and cables from the ...

Page 96: ...10 2 902997 Figure 10 1 Control Panel Assembly Type E R7086 PDC 20A PDC 20 PDC 25 PDC 30 TYPE E ...

Page 97: ...902997 10 3 Figure 10 2 Control Panel Assembly Type EE R7087 PDC 20A PDC 20 PDC 25 PDC 30 TYPE EE ...

Page 98: ...10 4 902997 Figure 10 3 Control Panel Assembly Type E R7088 PDC 40 TYPE E ...

Page 99: ...902997 10 5 Figure 10 4 Control Panel Assembly Type EE R7089 PDC 40 TYPE EE ...

Page 100: ...bolt through bot tom of front molding 4 and slide molding onto frame 2 2 Attach coil 11 to frame 2 with flat washer and 5 8 inch long hex head bolt Be sure braid assembly 3 has been attached to frame 2 with 3 4 inch bolt lock washer flat washer and nut Use 10 mm wrench on nut 3 Attach frame 2 to base molding 1 by engaging slots of bottom of frame 2 behind flanges near lower edge of base molding 1 ...

Page 101: ...NOTE Removal procedures are covered in SEC TION 7 Refer to Figure 12 42 for motor disassembly 10 4 BATTERIES 1 Turn key to off and remove from key switch NOTE Batteries are heavy Use care when lifting out of battery compartment 2 Disconnect the battery quick disconnect 2 Fig ure 10 6 3 Lift the battery out of the battery compartment 4 Lower the new battery in the battery compart ment 5 Reconnect t...

Page 102: ... from bracket and then disconnect wiring from the switch 3 Connect the wiring to the new switch and install the switch onto the bracket NOTE Bracket must be positioned so that switch is operated when lift carriage is down 4 Position bracket with new switch in place on frame and secure with two washers two lock washers and two screws Figure 10 6 Mast Related Electrical Components R1337 ...

Page 103: ...to Figure 12 50 for replacement parts and to the dia grams Figure 4 3 Figure 4 4 Figure 4 5 or Figure 4 6 for wiring information 11 3 BATTERY CAPACITY INDICATOR Refer to Figure 12 51 and Figure 12 52 for the battery capacity indicator replacement parts 11 4 HAND HELD REMOTE CONTROL Refer to Figure 12 49 for removal and parts identifica tion of the hand held remote control option 11 5 AUXILIARY HYD...

Page 104: ...11 2 902997 NOTES ...

Page 105: ...902997 12 1 SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the PDC Lift Truck ...

Page 106: ...12 2 902997 Figure 12 1 Control Head Assembly R6089 SEE FIGURE 12 2 FOR SWITCHS SEE FIGURE 12 3 FOR COLD CONDITIONING ...

Page 107: ...63 FLAT HD SLOTTED SCREW 6 32 X 1 2 24 069478 PHILLIPS FLAT HD SCREW 1 4 20 X 3 4 4 25 069715 SOCKET FLAT HD SCREW 1 4 20 X 3 4 2 26 070486 PAN HD SCREW BRASS 2 27 072400 01 SLOTTED HEX SCREW 6 32 X 1 2 4 28 072414 SLOTTED PAN HD SCREW 1 29 072415 PAN HD SCREW THREAD CUT TING 4 40 X 5 8 1 30 073461 SOCKET SET SCREW 2 31 074711 CONNECTING ROD SPACER 1 32 075088 RETURN SPRING 1 33 075510 COMPRESSION...

Page 108: ...RED 1 4 021208 TERMINAL 4 MAX 5 023014 WIRE A R 6 053215 02 HOLE PLUG 1 7 053215 03 HOLE PLUG 1 8 056619 01 HORN DECAL 1 9 056641 03 LIFT DECAL 1 10 056641 04 LOWER DECAL 1 11 067415 PAN HD SCREW 6 32 X 1 4 A R 12 067416 PAN HD SCREW 5 32 X 1 2 4 13 402830 TOP COVER 1 14 402831 TOP COVER 1 15 402832 TOP COVER 1 16 402842 SWITCH PLATE 1 A R AS REQUIRED INDEX NO PART NO PART NAME NO REQD ...

Page 109: ...14 WIRE A R 4 400544 BRACKET RESISTOR 1 5 018214 INSULATOR SWITCH 1 6 402829 BRACKET 1 7 077007 WASHER 2 8 077204 SPLIT LOCK WASHER 6 2 9 072400 01 HEX HD SLOTTED SCREW 6 32 X 1 2 2 10 059632 NUT HEX 5 40 2 11 400044 BRACKET THERMAL CUTOUT 1 12 020736 THERMAL CUTOUT SWITCH 1 13 005643 CONTACT PIN 2 A R AS REQUIRED INDEX NO PART NO PART NAME NO REQD ...

Page 110: ...12 6 902997 Figure 12 4 Steering Arm HANDLE RETURN SPRING KIT 901325 CONTAINS ITEM QTY 4 1 5 1 6 2 7 2 14 1 15 1 R5994 ...

Page 111: ...N COTTER 2 9 060300 PIN CLEVIS 1 10 052876 BUMPER 2 11 071377 SCREW 10 32 X 3 4 3 12 056200 CLEVIS 1 13 800275 HANDLE 1 14 285302 PIN SPRING 1 15 285303 PIN SPRING 1 16 800204 CLAMP 1 17 402363 ARM PIVOT 1 18 052925 BEARING FLANGED 1 19 052922 BEARING FLANGED 1 20 501673 ROD BRAKE 1 21 069478 SCREW HEX CAP 1 4 20 X 3 4 1 22 402459 COVER PIVOT CAP 1 23 061716 SNAP RING 2 24 402452 PIN 1 HANDLE RETU...

Page 112: ... UPPER 1 4 061002 ROLL PIN 1 4 X 3 4 1 5 053108 BUSHING LOWER 1 6 051146 BEARING THRUST 1 7 505681 01 PIVOT TUBE WELDMENT 1 8 064709 SCREW HEX HEAD 1 2 13 X 1 1 2 4 9 077412 LOCKWASHER EXTERNAL 4 10 025712 FITTING GREASE 1 11 DRIVE MOTOR FIGURE 12 42 REF 12 DRVIE WHEEL FIGURE 12 7 REF 13 TRANSMISSION FIGURE 12 7 REF INDEX NO PART NO PART NAME NO REQD ...

Page 113: ...902997 12 9 NOTES ...

Page 114: ...12 10 902997 Figure 12 6 Brake and Linkage R3297 ...

Page 115: ...DISC ASSEMBLY 1 20 077215 LOCKWASHER SPLIT 5 8 6 21 059645 LOCKNUT 5 8 18 1 22 077210 LOCKWASHER 5 16 4 23 063567 SCREW CAP HEX HEAD 5 16 18 X 1 1 4 4 24 077211 LOCKWASHER 3 8 2 25 064605 HEX HEAD CAP SCREW 3 8 16 X 1 HEAT TREATED 2 26 800119 CLEVIS 1 27 052821 DISC BRAKE CALIPER ASSEMBLY 1 28 059421 NUT HEX 1 4 20 2 29 077209 LOCKWASHER 2 30 901189 BOLT 2 31 901190 SPACER 2 32 901191 SPRING 2 33 ...

Page 116: ...12 12 902997 Figure 12 7 Standard Transmission Assembly R4702 ...

Page 117: ...6 X 1 3 4 7 20 036106 BEARING COVER GASKET 1 21 051159 BEARING COVER 1 22 063555 HEX HEAD CAP SCREW 5 16 18 X 1 4 23 077210 LOCK WASHER 5 16 4 24 064620 HEX HEAD CAP SCREW 3 8 16 X 3 3 4 2 25 064615 HEX HEAD CAP SCREW 3 8 16 X 2 1 4 2 26 060428 COTTER PIN 1 27 059745 HEX NUT 5 8 18 1 28 057234 MOTOR PINION SPUR 1 30 060585 DOWEL PIN 2 31 800072 TRANSMISSION HOUSING 1 32 026304 FILL PLUG 1 500935 D...

Page 118: ...12 14 902997 Figure 12 8 Base Frame R1342M YELLOW PAINT PART NUMBER 901201 YELLOW PAINT PART NUMBER 901201 TRUCKS FROM 2011 BLACK PAINT PART NUMBER 901202 ...

Page 119: ...TUBE HOUSING 1 17 VAR BATTERY SPACER 1 18 VAR BODY 1 19 NOT USED 20 077029 WASHER 11 GA 1 21 077074 WASHER 14 GA 1 22 056479 LIFT DECAL 1 23 NOT USED 24 NOT USED 25 505678 HYDR COMPARTMENT COVER 1 26 005401 BATTERY CONNECTOR 1 27 068480 ROUND HEAD MACHINE SCREW 1 4 28 X 1 2 28 VAR NAME PLATE 1 29 066050 ROUND HEAD MACHINE SCREW 4 30 056592 WARNING DECAL 1 31 069712 SCREW FLAT HD 4 32 077056 WASHER...

Page 120: ...12 16 902997 Figure 12 9 Decal Location R6501 ...

Page 121: ...SCREW DRIVE RD HD 2U X 1 4 8 6 056646 DECAL CAUTION BATTERY 1 7 061299 NAMEPLATE FM 1 8 056626 DECAL OIL LEVEL 1 9 056499 DECAL NO RIDING 1 10 056625 DECAL WARNING 1 11 056633 DECAL MAST BIG JOE LARGE 2 12 056634 DECAL TRIMAST 2 13 056494 DECAL WARNING LWR FORKS 1 056683 DECAL AMERICAN BUILT 2 056696 DECAL BIG JOE SUPPORT 2 900598 DECAL KIT PART OF KIT NUMBER 900598 INDEX NO PART NO PART NAME NO R...

Page 122: ...L 2 2 051141 BEARING CONE 2 3 051142 BEARING CUP 2 503389 WHEEL ASSY POLYURETHANE 2 4 800202 HUB 1 5 079163 POLYURETHANE WHEEL 10 1 2 IN 1 6 051144 BEARING CUP 2 7 051143 BEARING CONE 2 8 077124 WASHER 2 9 059128 LOCKNUT 2 10 053400 DUST CAP 2 11 074810 SPINDLE 2 INDEX NO PART NO PART NAME NO REQD ...

Page 123: ...05807 RAM HEAD ASSEMBLY 1 9 057761 RAM HEAD 1 10 051120 BEARING 2 11 074251 SHEAVE 2 12 077022 FLAT WASHER 2 13 061728 RETAINING RING 2 13A 025712 GREASE ZERK 2 14 402051 ADJUSTING BOLT 2 15 059545 SPLIT LOCK WASHER 5 8 2 16 077215 SPLIT LOCK WASHER 5 8 2 17 059445 HEX NUT 5 8 18 2 18 402034 LIFT CHAIN LIFT HEIGHT 60 IN CHAIN LENGTH 3 4 FT 2 19 059429 HEX NUT 3 8 16 2 20 101072 CYLINDER CLAMP 1 21...

Page 124: ...12 20 902997 Figure 12 12 Elevation System Non Telescopic R2030 PDC 20A PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 4454693 4471137 AND HIGHER PDC 40 LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER ...

Page 125: ...13 FLAT WASHER 4 11 061729 EXTERNAL RETAINING RING 2 12 289202 SHEAVE 2 13 025712 GREASE FITTING 2 14 312203 ADJUSTING BOLT 2 15 059547 JAM NUT 3 4 16 2 16 077217 LOCK WASHER 3 4 2 17 059447 HEX NUT 3 4 16 2 18 059429 HEX NUT 3 8 16 2 19 402043 01 CYLINDER CLAMP 1 20 402322 SWITCH BRACKEY 1 21 063478 HEX HEAD CAP SCREW 1 4 20 X 3 4 2 22 077209 LOCK WASHER 1 4 2 23 503921 01 OUTER MAST 1 24 LIFT CY...

Page 126: ...12 22 902997 Figure 12 13 Elevation System Telescopic R1329 PDC 20A PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 384041 TO 4456482 ...

Page 127: ... 17 191089 STOP BLOCK 2 18 077209 LOCK WASHER 1 4 4 19 059421 HEX NUT 1 4 20 4 20 100016 SPACER 2 21 064711 SCREW HEX HEAD 1 2 13 X 1 3 4 1 22 077213 LOCK WASHER 1 2 1 505806 RAM HEAD ASSY 1 23 505805 RAM HEAD 1 24 051120 BEARING 2 25 074251 SHEAVE 2 26 077022 FLAT WASHER 2 27 061728 RETAINING RING 2 28 402051 ADJUSTING BOLT 2 29 059545 JAM NUT 5 8 18 2 30 077215 LOCKWASHER 5 8 2 31 059445 HEX NUT...

Page 128: ...12 24 902997 Figure 12 14 Elevation System Telescopic R2031 PDC 20A PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 4454693 4471137 AND HIGHER PDC 40 LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER ...

Page 129: ...AT TREATED 4 19 062320 BEARING 8 20 077077 THRUST WASHER 0 09 THK A R 20 077078 THRUST WASHER 0 12 THK A R 20 077079 THRUST WASHER 0 15 THK A R 20 077080 THRUST WASHER 0 18 THK A R 21 239520 BAR CLAMP 1 22 100016 SPACER 2 23 069607 FLAT HEAD MACHINE SCREW 3 8 16 X 1 1 2 4 24 191162 STOP BLOCK 2 24A 402812 STOP BLOCK SHIM PLATE A R 25 402322 SWITCH BRACKET 1 26 063478 HEX HEAD CAP SCREW 1 4 20 X 3 ...

Page 130: ...12 26 902997 Figure 12 15 Elevation System Full Free Lift R1343M PDC 20A PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 384041 TO 4456482 ...

Page 131: ...ARING 2 15 074269 SHEAVE 2 16 NOT USED 17 061729 EXTERNAL RETAINING RING 2 18 060402 COTTER PIN 1 16 X 3 8 4 19 402055 CLEVIS PIN 0 200 DIA X 1 4 20 402051 CHAIN BOLT 2 21 059545 JAM NUT 5 8 16 2 22 077215 LOCK WASHER 5 8 2 23 059445 HEX NUT 5 8 18 2 24 061020 ROLL PIN 1 25 402034 LIFT CHAIN LIFT HEIGHT 106 IN CHAIN LENGTH 5 38 FT LIFT HEIGHT 130 IN CHAIN LENGTH 6 88 FT 7 26 CABLE A R 27 NOT USED ...

Page 132: ...12 28 902997 Figure 12 16 Elevation System Full Free Lift R1609 PDC 20A PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 4471137 AND HIGHER PDC 40 LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER ...

Page 133: ...712 GREASE FITTING 2 17 503712 COLLAR SHEAVE 1 18 060314 CHAIN CLEVIS PIN 4 19 064609 HEX HEAD CAP SCREW 3 8 16 X 1 1 2 HEAT TREATED 1 20 312203 ADJUSTING BOLT 2 21 059547 NUT JAM 3 4 16 2 22 401895 CARRIAGE STOP 2 23 059447 HEX NUT 3 4 16 2 24 0610200 ROLL PIN 1 25 063480 HEX HEAD CAP SCREW 1 4 20 X 1 1 26 800257 CABLE CLAMP 1 27 077209 LOCK WASHER 1 4 1 28 059421 HEX NUT 1 4 20 1 29 077011 WASHE...

Page 134: ...12 30 902997 Figure 12 17 Elevation System Clear View TRIMAST R6924 ...

Page 135: ...5 16 2 24 059426 NUT HEX 5 18 18 2 25 063712 SCREW HEX 1 2 13 X 2 1 4 2 26 077213 WASHER LOCK SPLIT 1 2 2 27 064507 SCREW HEX 3 8 16 X 1 25 2 28 312203 CHAIN LUG ADJUSTING 2 29 060314 PIN W RETAINING RINGS 4 30 064609 SCREW HEX 3 8 16 x 1 1 2 4 31 506627 01 OUTER MAST 158 LIFT 1 31 506627 02 OUTER MAST 194 LIFT 1 31 506627 03 OUTER MAST 212 LIFT 1 32 506106 01 CENTER MAST 158 LIFT 1 32 506106 02 C...

Page 136: ...AST FULL FREE LIFT R7044 R5067 PDC 20A PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 384041 to 4459343 PDC 20A PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 384041 to 4459343 PDC 20A PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER ALL LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER R7045 ...

Page 137: ... 32 IN WIDE 1 12 503697 LOAD BACKREST 35 IN WIDE 1 12 505990 LOAD BACKREST 36 IN WIDE 1 13 077215 LOCK WASHER 5 8 4 14 063820 HEX HEAD CAP SCREW 4 15 077066 ROUND WASHER 2 16 057115 HOOK TYPE FORK 30 X 1 1 2 2 16 057172 HOOK TYPE FORK 36 X 1 1 2 2 16 057173 HOOK TYPE FORK 42 X 1 1 2 2 16 057174 HOOK TYPE FORK 48 X 1 1 2 2 17 401527 BAR FORK RETAINER TRUCKS WITHOUT BACKREST 2 18 025712 GREASE FITTI...

Page 138: ... TRUCKS SERIAL NUMBERS 4454693 4471137 AND HIGHER PDC 15 PDC 20 PDC 25 PDC 30 LIFT TRUCKS SERIAL NUMBERS 4454693 4471137 AND HIGER PDC 15 PDC 20 PDC 25 PDC 30 PDC 40 LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER ALL LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER R7044 PDC 40 LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER PDC 40 LIFT TRUCKS SERIAL NUMBERS 384041 AND HIGHER ...

Page 139: ...0 2 16 057172 HOOK TYPE FORK 36 X 1 3 4 PDC 15 20 25 30 2 16 057173 HOOK TYPE FORK 42 X 1 3 4 PDC 15 20 25 30 2 16 057174 HOOK TYPE FORK 48 X 1 3 4 PDC 15 20 25 30 2 16 057159 HOOK TYPE FORK 30 X 1 3 4 PDC 40 2 16 057129 HOOK TYPE FORK 36 X 1 3 4 PDC 40 2 16 057112 HOOK TYPE FORK 42 X 1 3 4 PDC 40 2 16 057113 HOOK TYPE FORK 48 X 1 3 4 PDC 40 2 16 057116 HOOK TYPE FORK 60 X 1 3 4 PDC 40 2 17 401527...

Page 140: ...12 36 902997 Figure 12 20 Standard Control Valve R7046 ...

Page 141: ...LVE LH 1 6 506740 LEVER VALVE RH 1 7 401220 SPACER TUBE 1 8 060425 PIN COTTER 1 9 060317 PIN CLEVIS 1 10 059421 NUT HEX 1 4 20 4 11 077209 WASHER LOCK SPLIT 1 4 4 12 060402 PIN COTTER 2 13 060335 PIN CLEVIS 2 14 VALVE 2 SPOOL FIGURE 12 21 REF 15 SWITCH SPOOL VALVE FIGURE 12 22 REF 16 023324 WIRE HARNESS SPOOL VALVE 1 17 065476 SCREW HEX HD 1 4 20 X 1 2 4 INDEX NO PART NO PART NAME NO REQD ...

Page 142: ...E LIFT NO REQD VALVE 2 SPOOL 048188 048189 1 1 INLET SECTION WITH PLUG 907218 01 1 2 INLET SECTION WITHOUT PLUG 907218 02 1 3 LIFT SECTION FIGURE 12 22 907218 03 907218 03 1 4 TILT SECTION FIGURE 12 22 907218 04 907218 04 1 5 OUTLET SECTION 907218 05 907218 06 SEAL KIT 907214 907215 4 R7124 ...

Page 143: ...re 12 22 Valve Section INDEX NO PART NAME LIFT SECTION TILT SECTION NO REQD LIFT 907218 03 1 TILT 907218 04 1 1 SWITCH 907210 907210 1 2 CLEVIS END 907218 07 907218 07 1 3 BRACKET WITH SCREWS 907218 08 907218 08 1 R7125 ...

Page 144: ... 902997 Figure 12 23 Hydraulic System Non Telescopic and Telescopic R2026M PDC 20A PDC 20 PDC 25 PDC 30 1 SEE SUPPLEMENT 269 FOR OPTIONAL AUXILIARY HYDRAULICS 2 SEE SUPPLEMENT 337 FOR ADDITIONAL INFORMATION ...

Page 145: ...2 20 1 22 060335 CLEVIS PIN FIGURE 12 20 2 23 063480 HEX HEAD CAP SCREW 1 4 20 x 1 3 24 077209 LOCK WASHER 1 4 3 25 060403 COTTER PIN 1 16 x 1 2 2 26 059628 HEX NUT 5 16 18 2 27 505687 THROTTLE VALVE COVER 1 28 072413 PAN HEAD SCREW 4 40 X 1 2 4 29 056635 DECAL VALVE 1 30 056637 02 DECAL TILT 1 31 056637 01 DECAL LIFT 1 32 065538 SCREW 5 16 18 X 5 8 9 33 HYDRAULIC PANEL ASSEMBLY FIGURE 12 31 REF 3...

Page 146: ...12 42 902997 Figure 12 24 Hydraulic System Non Telescopic and Telescopic R2027M PDC 40 1 SEE SUPPLEMENT 269 FOR OPTIONAL AUXILIARY HYDRAULICS 2 SEE SUPPLEMENT 337 FOR ADDITIONAL INFORMATION ...

Page 147: ...77209 LOCK WASHER 1 4 3 30 060402 COTTER PIN FIGURE 12 20 2 31 060335 CLEVIS PIN FIGURE 12 20 2 32 059628 HEX NUT 5 16 18 2 33 065538 SCREW 5 16 18 X 5 8 9 34 072413 PAN HEAD SCREW 4 40 X 1 2 4 35 056635 DECAL VALVE 1 36 056637 02 DECAL TILT 1 37 056637 01 DECAL LIFT 1 38 505687 THROTTLE VALVE COVER 1 39 HYDRAULIC PANEL ASSEMBLY FIGURE 12 31 REF 40 025501 ELBOW 1 4 NPT TUBE 90 2 41 282500 TUBING V...

Page 148: ...12 44 902997 Figure 12 25 Hydraulic System Full Free Lift R2028M PDC 20 PDC 25 PDC 30 1 SEE SUPPLEMENT 269 FOR OPTIONAL AUXILIARY HYDRAULICS 2 SEE SUPPLEMENT 337 FOR ADDITIONAL INFORMATION ...

Page 149: ...E 12 20 REF 22 LIFT CONTROL LEVER FIGURE 12 20 REF 26 CLEVIS PIN FIGURE 12 20 REF 29 COTTER PIN FIGURE 12 20 REF 30 059628 HEX NUT 5 16 18 2 31 072413 PAN HEAD SCREW 4 40 X 1 2 4 32 056635 DECAL VALVE 1 33 056637 02 DECAL TILT 1 34 056637 01 DECAL LIFT 1 35 505687 THROTTLE VALVE COVER 1 36 065538 SCREW 5 16 18 X 5 8 9 37 HYDRAULIC PANEL ASSEMBLY FIGURE 12 31 REF 38 026303 HEX SOCKET PLUG 1 4 1 39 ...

Page 150: ...12 46 902997 Figure 12 26 Hydraulic System Full Free Lift R2029M PDC 40 1 SEE SUPPLEMENT 269 FOR OPTIONAL AUXILIARY HYDRAULICS 2 SEE SUPPLEMENT 337 FOR ADDITIONAL INFORMATION ...

Page 151: ...EVER FIGURE 12 20 REF 34 065538 SCREW 5 16 18 X 5 8 9 35 505687 THROTTLE VALVE COVER 1 36 056637 01 DECAL LIFT 1 37 056637 02 DECAL TILT 1 38 056635 DECAL VALVE 1 39 072413 PAN HEAD SCREW 4 40 X 1 2 4 40 026303 HEX SOCKET PLUG 1 4 1 41 HYDRAULIC PANEL ASSEMBLY FIGURE 12 31 REF 42 025526 ELBOW 45 1 4 JIC 2 43 027110 UNION TEE 1 4 1 44 025120 ELBOW 3 8 90 SWIVEL NUT 1 45 025524 ELBOW 90 1 4 JIC 3 46...

Page 152: ...12 48 902997 Figure 12 27 Hydraulic System Clear View TRIMAST Sheet 1 R6925A PDC 20 PDC 25 PDC 30 ...

Page 153: ...902997 12 49 Figure 12 27 Hydraulic System Clear View TRIMAST Sheet 2 R6925B PDC 20 PDC 25 PDC 30 ...

Page 154: ...E MALE 1 4 NPT 1 4 JIC 2 31 025548 ELBOW 90 MALE 1 2 JIC 1 32 027104 TEE MALE 3 8 JIC 1 33 506635 02 TUBE ASSY HYDRAULIC 3 8 LH 1 34 506635 01 TUBE ASSY HYDRAULIC 3 8 RH 1 35 077031 WASHER FLAT 1 4 2 36 063478 SCREW HX HD 1 4 20 X 3 4 3 37 405071 BRACKET MANIFOLD MAST 1 38 505086 03 HOSE HYDR PRESSURE 3 8 ID 1 39 505621 02 HOSE HYDR PRESSURE 1 2 ID 1 40 056106 CLAMP HOSE MINI 2 41 059426 NUT HEX 5...

Page 155: ... 03 TUBE ASSY 212 IN LIFT 1 INDEX NO PART NO PART NAME NO REQD 85 506621 01 HOSE ASSY 158 IN LIFT 1 85 506621 08 HOSE ASSY 194 IN LIFT 1 85 506621 08 HOSE ASSY 212 IN LIFT 1 86 504314 02 HOSE TILT FORWARD 42 BASE 1 86 504314 04 HOSE TILT FORWARD 48 BASE 1 86 504314 06 HOSE TILT FORWARD 54 BASE 1 87 026128 NIPPLE HOSE 3 8 1 88 026707 ELBOW 1 89 025111 STRAIGHT FITTING 3 8 1 90 025120 ELBOW 2 91 026...

Page 156: ...12 52 902997 Figure 12 28 Hydraulic System Clear View TRIMAST Sheet 1 R6926A PDC 40 ...

Page 157: ...902997 12 53 Figure 12 28 Hydraulic System Clear View TRIMAST Sheet 2 R6926B PDC 40 ...

Page 158: ...G MAST 1 43 026912 CONNECTOR MALE 3 8 NPT 3 8 JIC 2 44 047104 REGULATOR FLOW 5 GPM 2 45 026500 REDUCER PIPE 3 8 TO 1 4 2 46 025546 ELBOW MALE 1 4 NPT 2 47 061725 RING SNAP EXTL 1 SHAFT 4 48 296601 PIN REAR TILT RAM 2 49 025526 ELBOW 45 MALE 1 4 NPT 1 4 JIC 2 50 025524 ELBOW 90 MALE 1 4 NPT 1 4 JIC 4 51 296602 PIN FRONT TILT RAM 2 52 060976 PIN ROLL 3 16 X 1 50 2 53 056137 01 TIE CABLE AR 54 076704...

Page 159: ...506741 LEVER VALVE FIGURE 12 20 REF INDEX NO PART NO PART NAME NO REQD 93 506740 LEVER VALV FIGURE 12 20 1 94 060402 COTTER PIN FIGURE 12 20 2 95 060335 CLEVIS PIN FIGURE 12 20 2 96 048194 VALVE SE NOTE 1 NOTE REMOVE STEEL PLUG FROM VALVE AND REPLACE WITH VALVE INDEX NO PART NO PART NAME NO REQD ...

Page 160: ...12 56 902997 Figure 12 29 Remote Control Option Hydraulic Assemblies R7083 NON TEL TEL FFL ...

Page 161: ... NUT 5 40 059410 059410 4 15 PLUG FEMALE FLUSH MOUNT 017800 017800 2 16 REMOTE ASSY PUSHBUTTON 501736 501736 1 17 TERMINAL RING 6 021236 021236 6 18 NOT USED 19 SOLENOID VALVE SPOOL 048166 02 048166 02 048166 02 048166 02 1 21 REDUCER 025135 025135 025135 025135 1 22 ELBOW 90 025535 025535 025535 025535 1 23 HOSE COUPLING 3 8 JIC SWVL 026917 026917 026917 026917 4 24 HOSE 028900 028900 028900 0289...

Page 162: ...12 58 902997 Figure 12 30 Remote Control Option Hydraulic Assemblies R7082 CLEAR VIEW TRIMAST ...

Page 163: ...9 18 CONNECTOR INLINE INSUL 005422 005422 005422 4 19 SOLENOID VALVE 048166 02 048166 02 048166 02 1 20 TERMINAL RING 3 16 16 GA 021203 021203 1 21 REDUCER 025135 025135 025135 22 ELBOW 90 025535 025535 025535 1 23 HOSE COUPLING 3 8 JIC SWVL 026917 026917 026917 4 24 HOSE 028900 028900 028900 A R 25 HOSE 1 2 283100 283100 283100 A R 26 FITTING 026930 026930 026930 A R 27 VALVE ASSY SEE FIGURE 12 2...

Page 164: ...12 60 902997 Figure 12 31 Hydraulic Panel Assembly R7084 ...

Page 165: ...LOCK WASHER 3 8 4 14 059429 HEX NUT 3 8 16 4 15 026109 NIPPLE HOSE 3 8 1 16 025542 ELBOW FEMALE 90 1 17 056105 HOSE CLAMP SCREW TYPE 2 18 318200 HOSE 3 4 1 19 800145 NIPPLE 1 20 035114 SUMP FILTER 1 21 026302 DRAIN PLUG 1 22 505831 HYDRAULIC RESERVOIR 1 23 403665 PAD 4 24 059421 HEX NUT 1 4 20 1 25 077208 LOCK WASHER 1 4 1 26 026146 NIPPLE 3 4 14 1 27 026512 THREADED REDUCER 1 28 063478 HEX HEAD C...

Page 166: ...2 24VPDC S N 4446093 AND HIGHER NO REQD PUMP AND MOTOR ASSEMBLY 016913 016973 1 1 MOTOR FIGURE 12 41 REF 2 PUMP 900896 09 906012 1 3 LOCK WASHER 5 16 077210 077210 4 4 HEX HEAD SCREW 5 16 18 X 3 4 063553 063553 4 PUMP 906012 USES ONLY 2 EACH OF ITEMS 3 4 WHICH ARE SUPPLIED WITH PUMP R7085 ...

Page 167: ...902997 12 63 NOTES ...

Page 168: ...12 64 902997 Figure 12 33 Lift Cylinder Assembly Non Telescopic and Telescopic 2 75 DIA CYL PACKING KIT 907119 2 50 DIA CYL PACKING KIT 907121 CONTAIN ITEM QTY 2 1 4 1 7 1 11 1 15 1 R6106 NON TEL TEL ...

Page 169: ...5 02 042205 02 042205 02 042205 02 042205 02 1 2000 2500 and 3000 lb Lift 2 3 4 inch I D cylinder with 2 1 4 inch diameter rod On Trucks SERIAL NUMBER 4456483 4471137 AND HIGHER 4000 LB Lift 2 3 4 inch I D cylinder with 2 1 4 inch diameter rod On Trucks SERIAL NUMBER 384041 AND HIGHER INDEX NO PART NAME 60 INCH LIFT 106 INCH LIFT 130 INCH LIFT 154 INCH LIFT 168 INCH LIFT NO REQD HYD LIFT CYLINDER ...

Page 170: ...12 66 902997 Figure 12 34 Lift Cylinder Assembly Full Free Lift Telescopic PACKING KIT 907211 CONTAINS ITEM QTY 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 R7093 FULL FREE LIFT ...

Page 171: ... NUT 1 4 BACKUP WASHER 1 5 ROD WIPER 1 6 POLYPACK 1 7 BACKUP WASHER 1 8 0 RING 1 9 WEAR RING 1 10 PSC SEAL 1 11 0 RING 1 12 BACKUP WASHER 1 13 WEAR RING 2 14 GLAND NUT 1 15 OUTER JACKET TUBE 1 16 FELT RING NOT IN PACKING KIT 1 17 PRIMARY ROD 1 18 GLAND NUT 1 19 SECONDARY ROD 1 20 FLOW REGULATOR 1 21 ROD END 1 CONTAINED IN PACKING KIT PART NUMBER 907211 ...

Page 172: ...EX NO PART NO PART NAME NO REQD 503600 01 SECONDARY LIFT CYLINDER 158 LIFT 2 503600 02 SECONDARY LIFT CYLINDER 194 LIFT 2 1 049508 WIPER RING 1 2 800023 GLAND NUT 1 3 042122 O RING 1 4 VAR PISTON ROD 1 5 296001 01 RAM STOP 1 6 042105 O RING 1 7 403863 PISTON 1 8 042205 01 SEAL 1 9 800293 JAM NUT 3 4 16 1 10 VAR TUBE ASSEMBLY 1 INDEX NO PART NO PART NAME NO REQD ...

Page 173: ...6617 01 FULL FREE LIFT LIFT CYLINDER 158 LIFT 2 506617 02 FULL FREE LIFT LIFT CYLINDER 194 LIFT 2 1 049502 WIPER RING 1 2 800049 GLAND NUT 1 3 042114 O RING 1 4 VAR PISTON ROD 1 5 272205 RAM STOP 158 LIFT 1 5a 272214 RAM STOP 194 212 LIFT 1 6 042105 O RING 1 7 403949 PISTON 1 8 042205 03 SEAL 1 9 800293 JAM NUT 3 4 16 1 10 VAR TUBE ASSEMBLY 1 11 907130 SWITCH LIMIT 1 INDEX NO PART NO PART NAME NO ...

Page 174: ... 1 2 POLYPAK 2 3 901065 PISTON ALUM 1 4 O RING 1 5 901062 SPACER 1 6 JACKET ASSEMBLY 1 7 901064 PISTON ROD 1 8 POLYPAK 1 9 O RING 1 10 901066 GLAND NUT 1 11 ROD WIPER 1 12 901068 ROD END 1 13 901063 GREASE ZERK 2 CONTAINED IN PACKING KIT PART NUMBER 901067 PACKING KIT 901067 CONTAINS ITEM QTY 2 2 4 1 8 1 9 1 11 1 R5073 EM MODEL ...

Page 175: ...COMPLETE CYLINDER ASSEMBLY 1 1 GREASE ZERK 2 2 BARREL 1 3 903250 NUT 1 4 SEAL 1 5 903252 PISTON 1 6 O RING 1 7 O RING 1 8 BACKUP RING 1 9 903251 HEAD 1 10 ROD SEAL 1 11 DUST SEAL 1 12 903254 RETAINING RNG 1 13 903255 PISTON ROD 1 14 903257 ROD END 1 15 BRASS SETSCREW 1 4 28 NYLOCK 1 CONTAINED IN PACKING KIT PART NUMBER 903253 INDEX NO PART NO PART NAME NO REQD ...

Page 176: ... CYLINDER ASSEMBLY 1 1 GREASE ZERK 2 2 BARREL 1 3 23075 NUT 1 4 30251 WEAR RING 1 5 22259 PISTON 1 6 21521 PSP SEAL 1 7 18116 O RING 1 8 047543 R PISTON ROD 1 9 18330 O RING 1 10 39330 BACKUP WASHER 1 11 21114 POLYPAK TYPE B 1 12 13533 GLAND NUT 1 13 12101 ROD WIPER 1 14 ROD END 1 SETSCREW 1 CONTAINED IN PACKING KIT PART NUMBER 901067 INDEX NO PART NO PART NAME NO REQD ...

Page 177: ...005405 STRAIN RELIEF PDC 40 1 2 005421 BATTERY QUICK DISCONNECT 1 3 005401 BATTERY CONNECTOR 1 4 020689 HIGH SPEED CUTOFF SWITCH COLD CONDITIONING ONLY 1 4 020703 HIGH SPEED CUTOFF SWITCH 1 5 021236 TERMINAL RING 6 2 6 020729 LIMIT SWITCH MICROSWITCH 1 7 NOT USED 1 8 004724 CABLE A R 9 TERMINAL RING 3 16 16 GA 4 A R AS REQUIRED R1337 ...

Page 178: ...10 32 4 7 LOCKWASHER 10 4 8 905058 HEAD COMMUTATOR END 4 9 SCREW RD HEAD 1 4 20 X 3 8 1 10 905059 BRUSH SET SERVICE 1 11 905060 BRUSH HOLDER PLATE 1 12 905061 SPRING SET BRUSH 1 13 905063 TERMINAL STUD PKG 1 14 905064 FIELD COIL INCLUDES HARDWARE 1 15 905065 WASHER SPRING 1 16 905066 BEARING COMMUTATOR END 1 17 905067 ARMATURE FAN ASSY 1 18 SCREW FILLISTER HEAD 10 32 X 3 4 8 19 905068 BEARING DRIV...

Page 179: ...69 BEARING 1 4 903266 RETAINING RING 1 5 903270 ARMATURE ASSEMBLY 1 6 903271 FRAME FIELD ASSEMBLY 1 7 903265 BRUSHLEAD TERMINAL 1 8 903258 BRUSH BOX ASSEMBLY 1 9 903260 BRUSH SPRING SET 1 10 903262 BRUSH SET 1 11 903263 BEARING 1 12 903272 WAVE WASHER 1 13 903273 COMMUTATOR ENDHEAD 1 14 903274 HEADBAND ASSEMBLY 1 INDEX NO PART NO PART NAME NO REQD ...

Page 180: ...5 10 14 10 13 3 11 10 1 2 13 14 STATUS MAX 15 AMP VIEW A A DIODE INSTL A A SOLDER 16 32 PUMP MOTOR SOLENOID CABLE TERMINAL 4 5 6 7 36 25 2 20 3 21 22 23 28 24 26 27 PUMP MOTOR NEG CABLE TERMINAL BATTERY CABLE NEG TERMINAL 31 CABLE A1 TERMINAL 17 18 19 1 15 34 30 CABLE S1 TERMINAL 29 CABLE S2 TERMINAL 35 BQTTERY CABLE POS TERMINAL 14 13 12 10 11 33 9 8 R7086 PDC 20A PDC 20 PDC 25 PDC 30 TYPE E ...

Page 181: ...2 17 059426 NUT HEX 5 16 18 4 18 077210 WASHER LOCK SPLIT 5 16 4 19 063552 SCREW HEX CAP 5 16 18 X 5 8 4 20 008904 FUSE HOLDER 1 21 077203 LOCK WASHER 1 22 056504 DECAL FUSE 15A 1 23 008910 15 AMP FUSE 1 24 023255 WIRE HARNESS ASSEMBLY 1 25 503965 82 CABLE ASSY 2 POS 1 26 503965 34 CABLE ASSY 2 A2 1 27 503965 06 CABLE ASSY 2 M 1 28 503965 45 CABLE ASSY 2 A2 1 29 503965 46 CABLE ASSY 2 S2 1 30 5039...

Page 182: ...S1 M MAX 300 AMP DELAY TYPE 9 10 C C B B A A SECTION A A SECTION B B 33 18 19 17 1 12 3 21 22 23 41 42 20 4 5 6 7 8 40 39 38 36 24 24 5 13 14 15 16 25 26 10 27 28 29 30 35 36 35 2 37 CABLE A1 TERMINATION PUMP MOTOR NEG CABLE TERMINATION BATTERY CABLE NEG TERMINATION 34 CABLE S2 TERMINATION CABLE A2 TERMINATION CABLE S1 TERMINATION POS A2 CABLE PUMP MOTOR SOLENOID TERMINATION 26 10 27 28 29 44 SECT...

Page 183: ...OR INLINE INSUL 3 21 063552 SCREW HEX CAP 5 16 18 X 5 8 4 22 059426 NUT HEX 5 16 18 4 22 059426 NUT HEX 5 16 18 4 23 077210 WASHER LOCK SPLIT 5 16 4 24 401181 BUS BAR 2 25 075621 STUD BRASS 1 4 20 X 1 7 8 5 26 059422 NUT HEX BRAS 1 4 20 UNC 2B 21 27 077105 FLAT BRONZE WASHER 32 28 402894 WASHER INSULATING 6 29 402895 WASHER SHOULDER INSULATING 6 30 008906 300 AMP FUSE 1 31 010613 TUBE INSULATING A...

Page 184: ...12 80 902997 Figure 12 45 Control Panel Assembly Type E R7088 PDC 40 TYPE E ...

Page 185: ...6507 FUSE DECAL 300 AMP 1 21 505321 SUPPRESSOR ASSY 1 22 070475 SCREW FD HD 1 4 20 X 3 8 4 23 005976 DIODE 2 24 005422 CONNECTOR INLINE INSUL 2 25 063552 SCREW HEX HD 5 16 18 X 5 1 2 26 059426 NUT HEX 5 16 18 4 27 077210 WASHER LOCK SPLIT 5 16 4 28 063553 SCREW HEX 5 16 18 X 3 4 2 29 008904 FUSE HOLDER 1 31 077203 LOCK WASHER 1 32 056504 DECAL FUSE 15A 1 33 008910 15 AMP FUSE 1 34 023204 WIRE HARN...

Page 186: ...12 82 902997 Figure 12 46 Control Panel Assembly Type EE R7089 PDC 40 TYPE EE ...

Page 187: ...10 WASHER LOCK SPLIT 5 16 4 24 401181 BUS BAR 2 25 075621 STUD BRASS 1 4 20 X 1 7 8 6 26 059422 NUT HEX BRASS 1 4 20 UNC 2B 24 27 077105 FLAT BRONZE WASHER 36 28 402894 WASHER INSULATING 6 29 402895 WASHER SHOULDER INSULATING 6 30 008906 300 AMP FUSE 1 31 010613 TUBING INSULATING A R 32 005976 DIODE 2 33 505320 DIODE ASSY 1 34 018409 02 RELAY 1 35 068177 SCREW RD HD 5 40 X 3 8 4 36 077203 LOCK WAS...

Page 188: ...RONT MOLDING WITH BLOWOUT 1 5 905015 ARMATURE PLATE RETAINER 2 6 905016 COMPRESSION SPRING 1 7 905017 SPRING STUD 1 8 905018 MOVING CONTACT ASSEMBLY 1 9 905019 ARMATURE PLATE 1 10 905020 POLE PIECE 1 11 905028 COIL ASSEMBLY 24 VOLTS 1 12 905022 FRONT CONTACT 1 13 905023 SPACER 1 14 401181 BUSBAR NOT PART OF CONTACTOR 1 16 905026 BACK CONTACT 1 17 905027 REAR MOLDING 1 FOR FORWARD REVERSE CONTACTOR...

Page 189: ...NO PART NAME NO REQD 1 019910 BUSHING STRAIN RELIEF TRUCKS WITH COLD CONDITIONING 1 1 005405 STRAIN RELIEF TRUCKS WITHOUT COLD CONDITIONING 1 2 020690 DEAD MAN SWITCH TRUCKS WITH COLD CONDITIONING 1 2 020729 DEAD MAN SWITCH TRUCKS WITHOUT COLD CONDITIONING 1 R1477 ...

Page 190: ...36 CONTROL STATION ASSEMBLY 1 1 800306 CONTROL BOX 1 2 058501 MAGNET 1 3 077407 LOCKWASHER 10 2 4 059416 HEX NUT 10 32 2 5 314003 COIL CORD 3 FEET 1 6 017801 MALE PLUG 1 7 052905 STRAIN RELIEF 1 8 067401 SCREW FILISTER HD 2 9 077030 WASHER FLAT 10 2 017800 PLUG FEMALE FLUSH MOUNT 2 R1353M ...

Page 191: ...902997 12 87 NOTES ...

Page 192: ...RE SPLICE INTO 7 WIRE 1 TO 7 WIRE OF CONTROL CABLE ASSY ROT AT ED 90 FROMPMOUNT ING POS IT ION NOTES LEAD MUST TERMINATE IN POSITION 3 OF 005647 CONNECTOR AT 505932 DIODE BLOCK ASSY 2 AFTER INSTALLATION OF DIODE ASSY MAKE SURE TRUCK CABLES WIRES ETC ARE CLEAR OF DIODES 1 8 WIRE FROM THE SPLICE ON PUMP SOLENOID HOUR METER WIRE CONNECTIONS ENLARGED VIEW A A 2 3 4 5 6 7 8 16 17 18 20 17 21 2 19 B B D...

Page 193: ...IT 10 2 8 077030 WASHER FLAT 10 2 9 505932 DIODE ASSEMBLY 1 10 505931 DIODE 1 11 403855 MOUNTING PLATE 1 12 010625 PAD INSULATING 1 13 068177 SCREW SL RD HD 5 40 X 3 8 2 14 077203 WASHER SPLIT LOCK 5 2 15 077007 WASHER 5 32 X 3 8 X 18 GA 2 16 071377 SCREW 10 32 X 3 4 2 17 015604 METER HOUR 1 18 068179 SCREW RD HD 5 40 x 5 8 3 19 504116 SUPPRESSOR ASSY 1 20 005422 CONNECTOR INLINE INSUL 2 21 021718...

Page 194: ...out Lockout INDEX NO PART NO PART NAME NO REQD 1 021718 CONNECTOR 2 3 021207 TERMINAL 2 4 023014 WIRE A R 5 010617 02 INDICATOR BAT CAPACITY 1 A R AS REQUIRED 4 5 TO 300 AMP FUSE AND BATTERY CONNECTOR 1 1 3 3 CONNECT TO B POWER TERMINAL OF TRANSISTOR CONTROLLER ON ELEC PANEL R5383 ...

Page 195: ...ART NO PART NAME NO REQD 1 021718 CONNECTOR 3 2 021203 TERMINAL 1 3 021207 TERMINAL 2 4 010618 02 INDICATOR BAT CAPACITY 1 6 023014 WIRE A R A R AS REQUIRED R5382 PUMP MOTOR SOLENOID 6 4 2 TO 300 AMP FUSE AND BATTERY CONNECTOR 1 3 S 3 CONNECT TO B POWER TERMINAL OF TRANSISTOR CONTROLLER ON ELEC PANEL ...

Page 196: ...LE 2 4 023018 WIRE BLACK 16 STRAINDED A R 5 021203 TERMINAL RING 2 6 023014 WIRE A R 7 005422 CONNECTOR IN LINE INSU LATED 1 8 021204 TERMINAL QUICK DISCONNECT FEMALE 2 9 023014 WIRE A R 10 021204 TERMINAL QUICK DISCONNECT FEMALE 2 11 005422 CONNECTOR IN LINE INSU LATED 1 12 056689 DECAL 1 13 020725 SWITCH KEY 1 900621 01 KEY SET A R 14 021203 TERMINAL RING 2 A R AS REQUIRED INDEX NO PART NO PART ...

Page 197: ......

Page 198: ...Big Joe Manufacturing Company ...

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