Big Joe PDI-2024 User Manual

Big Joe Manufacturing Company • Des Plaines, IL 60018 MANUAL NO. 901355
REV. B 0404
Manual Price $35.00
PDI SERIES
POWER DRIVE INTERMEDIATE
LIFT TRUCK
Serial Number 333375 to 376499
Operation
Maintenance
Repair Parts List
https://forklift-manuals.jimdofree.com

Big Joe PDI-2024 Specifications

General

Brand	Big Joe
Model	PDI-2024
Category	Forklifts
Language	English

Summary

Operator Instructions

Preparation for Use

Section 1: Description

1-3. Safety Features

Lists safety features designed for operator and payload protection.

Section 2: Operation

2-1. General

2-2. Operating Precautions

Lists critical safety warnings and precautions for operating the PDI lift truck.

2-3. Before Operation

Details important inspection points to check prior to operating the lift truck.

2-4. Power Drive Control Handle

Describes the function and components of the power drive control handle and steering arm.

2-5. Driving and Stopping Procedures

Outlines the step-by-step process for driving and stopping the PDI lift truck safely.

2-8. Lift/Lower Control

Explains how to operate the lift/lower control for forks.

2-9. Loading and Unloading

Provides procedures for loading and unloading materials with the lift truck.

Section 3: Planned Maintenance

3-2. Monthly and Quarterly Checks

Provides a chart for monthly and quarterly inspection and service tasks.

3-3. Wet Cell Battery Care

3-3.3. Smart Charger Operation

3-4.2. Charging Batteries

3-5. Lubrication

Refers to tables for recommended lubricants and items requiring lubrication.

3-6. Lift Chain Maintenance

Section 4: Troubleshooting

4-1. General

Introduces the troubleshooting guide and its categories.

4-2. Smart Charger 004978 Troubleshooting

Provides a logic flow for troubleshooting the smart charger.

4-3. Optional Gel Cell Battery Charger 004987 Troubleshooting

Details troubleshooting steps for the optional gel cell battery charger.

4-3.3. Circuit Breaker Testing

4-3.4. Power Transformer Testing

4-3.5. Circuit Board Testing

Explains the diagnostic test for the circuit board.

Section 5: Steering Arm and Control Heads Servicing

5-1. General

Covers adjustments, replacement, and repair of steering arm and control head components.

5-3. Belly-Button Switch Adjustment

5-4. Control Head Switch Replacement

Details replacing various switches within the control head assembly.

5-6. Steering Arm Return Spring Adjustment

5-7. Steering Arm Return Spring Replacement

5-8. Pivot Tube Flanged Bushing Replacement

5-9. Electrical Control Cable Replacement

Continues the procedure for replacing the electrical control cable.

Section 6: Brake Servicing

6-1. Adjustment

Explains how to adjust the mechanical brake if it doesn't hold properly.

6-2. Replacement of Disc Brake Parts

Details the procedure for replacing disc brake parts and assemblies.

Section 7: Transmission, Drive Wheel, Adjustable Straddle, and Load Wheel Servicing

7-1. Initial Disassembly

7-2. Drive Axle and Wheel Removal

7-3. Removal of Motor and Brake Assembly Including Drive Gear

Outlines the steps to remove the motor, brake, and drive gear assembly.

7-4. Removal of Brake Disc Assembly

7-6. Load Wheels

Section 8: Elevation System Servicing

8-2. Lift Chain Length Adjustment

Details adjusting lift chain length for telescopic and non-telescopic models.

8-2.2. Full Free Lift

Provides lift chain adjustment for full free lift models.

8-3. Lift Chain Wear Inspection

Explains how to inspect lift chains for wear and determine replacement needs.

8-4. Lift Chain Replacement

Details the procedure for replacing lift chains.

8-4.2. Full Free Lift

Describes lift chain replacement for full free lift models.

8-5. Lift Cylinder Removal

8-5.3. Full Free Lift

8-6. Ram Head Removal

8-8. Lubrication of Mast

Section 9: Hydraulic System Servicing

9-1. Relieving System Pressure

Details the procedure for safely relieving hydraulic system pressure before servicing.

9-2. Flow Control Valve Replacement

9-3. Suction Line Filter Replacement

9-4. Line or Fitting Replacement

9-5. Lift/Lower Control Valve

9-5.1. Adjustment

9-5.2. Disassembly

9-5.3. Pump Motor Switch Adjustment

9-6. Hydraulic Pump and Motor Assembly

Covers removal, installation, and pressure adjustment of the pump/motor assembly.

9-6.1. Pump and Motor Assembly Removal

9-6.2. Hydraulic Pressure Adjustment

Explains how to adjust hydraulic pump pressure.

9-7. Lift Cylinder Repair

Details the repair procedures for lift cylinders.

9-7.1. Non-Telescopic

9-7.2. Telescopic

9-7.3. Full Free Lift

Section 10: Electrical Components

10-1. Electrical Control Panels

10-2. Control Panel Servicing

10-3. Contactor Servicing

10-3.1. 2nd and 3rd Speed Contactor Disassembly

10-3.3. Forward-Reverse Contactor Disassembly

10-3.4. Forward-Reverse Contactor Reassembly

10-6. Battery Charger

10-7. Batteries