PDSR30

PDSR 30
POWER DRIVE REACH

LIFT TRUCK
Operation
Maintenance
Repair Parts List
Big Lift LLC MANUAL NO. BL-PDSR 30-0319 - 03-07-2019

www.bigjoeforklifts.com
TABLE OF CONTENTS
Section Page Section Page

1 DESCRIPTION ............................................................1-1 5-3 STEERING ARM................................................ 5-4
1-1 INTRODUCTION ................................................1-1 5-3.1 RETURN SPRING REPLACEMENT......... 5-4
1-2 GENERAL DESCRIPTION .................................1-1 5-3.2 STEERING ARM REMOVAL..................... 5-4
1-3 SAFETY FEATURES..........................................1-2 5-3.3 STEERING ARM INSTALLATION............. 5-4
2 OPERATION ...............................................................2-1 6 BRAKE SERVICING ................................................... 6-1

2-1 GENERAL...........................................................2-1 6-1 BRAKES............................................................. 6-1
2-2 OPERATING PRECAUTIONS............................2-1 6-1.1 AIR GAP ADJUSTMENT........................... 6-1
2-3 BEFORE OPERATION.......................................2-2 6-1.2 STOPPING DISTANCE ADJUSTMENT.... 6-2
2-4 GENERAL CONTROL OPERATION..................2-4 6-1.3 BRAKE ASSEMBLY REPLACEMENT ...... 6-2
2-5 DRIVING AND
STOPPING PROCEDURES...............................2-4 7 DRIVING SYSTEM ..................................................... 7-1
2-5.1 STOPPING ................................................2-4 7-1 DRIVE WHEEL .................................................. 7-1
2-6 BELLY-BUTTON SWITCH .................................2-5 7-2 TRANSMISSION................................................ 7-1
2-7 STEERING ARM GAS SPRING ........................2-5 7-3 STEERING MOTOR .......................................... 7-1
2-8 LIFT AND LOWER CONTROLS........................2-5 7-4 LOAD WHEEL.................................................... 7-1
2-9 LOADING AND UNLOADING.............................2-5 7-4.1 REMOVAL ................................................. 7-1
2-10 PARKING............................................................2-5 7-4.2 REPAIR ..................................................... 7-1
7-4.3 LOAD WHEEL INSTALLATION ................ 7-2
3 PLANNED MAINTENANCE ........................................3-1
3-1 GENERAL...........................................................3-1 8 ELEVATION SYSTEM SERVICING ........................... 8-1
3-2 MONTHLY AND QUARTERLY CHECKS..........3-1 8-1 GENERAL .......................................................... 8-1
3-3 BATTERY CARE ................................................3-1 8-2 LIFT CHAIN LENGTH ADJUSTMENT............... 8-1
3-3.1 GENERAL ..................................................3-1 8-3 LIFT CHAIN WEAR INSPECTION..................... 8-2
3-3.2 SAFETY RULES ........................................3-2 8-4 LIFT CHAIN REPLACEMENT............................ 8-2
3-3.3 BATTERY CARE AND CHARGING...........3-2 8-4.1 TELESCOPIC............................................ 8-2
3-3.4 BATTERY CLEANING ...............................3-2 8-4.2 TRIMAST FREE LIFT CHAIN.................... 8-4
3-4 CHARGING BATTERIES ..................................3-3 8-4.3 TRIMAST SECONDARY LIFT CHAIN ...... 8-4
3-5 LUBRICATION...................................................3-3 8-5 LIFT CYLINDERS .............................................. 8-4
3-6 LIFT CHAIN MAINTENANCE ............................3-3
9 HYDRAULIC SYSTEM SERVICING........................... 9-1
4 TROUBLESHOOTING ................................................4-1 9-1 LINES AND FITTINGS....................................... 9-1
4-1 GENERAL...........................................................4-1 9-2 HYDRAULIC PUMP,
4-2 CONTROLLER TROUBLESHOOTING ..............4-4 MOTOR AND RESERVOIR ............................... 9-6
4-2.1 ZAPI HANDSET (OPTIONAL) ...................4-4 9-2.1 REMOVAL ................................................. 9-6
4-2.2 FAULT DETECTION ..................................4-4 9-2.2 DISASSEMBLY AND REASSEMBLY ....... 9-6
4-2.2.1 GENERAL ............................................4-4 9-2.3 INSTALLATION ......................................... 9-6
4-2.2.2 LOGBOOK ACCESS............................4-4 9-2.4 LIFT CYLINDER (TELESCOPIC).............. 9-7
4-2.3 TESTING TRUCK OPERATION ................4-4 9-2.4.1 REMOVAL ........................................... 9-7
4-2.4 SETTINGS AND ADJUSTMENTS .............4-5 9-2.4.2 REPAIR ............................................... 9-7
4-2.4.1 SET OPTIONS .....................................4-5 9-2.4.3 INSTALLATION ................................... 9-7
9-2.5 LIFT CYLINDER (TRIMAST FREE LIFT).. 9-8
5 OPERATING CONTROL SYSTEM .............................5-1 9-2.5.1 REMOVAL ........................................... 9-8
5-1 CONTROL HEAD ...............................................5-1 9-2.5.2 REPAIR ............................................... 9-8
5-1.1 CAP ASSEMBLY REMOVAL.....................5-1 9-2.5.3 INSTALLATION ................................... 9-9
5-1.2 CAP ASSEMBLY INSTALLATION.............5-1 9-2.6 LIFT CYLINDER
5-1.3 CONTROL HEAD REMOVAL ....................5-1 (TRIMAST SECONDARY)......................... 9-9
5-1.4 CONTROL HEAD INSTALLATION ............5-1 9-2.6.1 REMOVAL ........................................... 9-9
5-1.5 POTENTIOMETER REPLACEMENT ........5-1 9-2.6.2 REPAIR ............................................... 9-9
5.1.6 BELLY-BUTTON 9-2.6.3 INSTALLATION ................................. 9-10
SWITCH REPLACEMENT .........................5-1 9-2.7 REACH CYLINDER................................. 9-10
5-1.7 HORN SWITCH REPLACEMENT .............5-4 9-2.7.1 REMOVAL ......................................... 9-10
5-1.8 LIFT AND LOWER 9-2.7.2 REPAIR ............................................. 9-10
SWITCH REPLACEMENT .........................5-4 9-2.7.3 INSTALLATION ................................. 9-15
5-2 COMPARTMENT COVERS ...............................5-4 9-2.8 TILT CYLINDER ...................................... 9-15
5-2.1 REMOVAL .................................................5-4 9-2.8.1 REMOVAL ......................................... 9-15
5-2.2 INSTALLATION..........................................5-4 9-2.8.2 REPAIR ............................................. 9-15
BL-PDSR 30-0319 - 03-07-2019 1

TABLE OF CONTENTS - CONTINUED
9-2.8.3 INSTALLATION ................................. 9-18

Section Page Section Page
10 ELECTRICAL COMPONENTS ................................. 10-1 10-3 PUMP MOTOR................................................. 10-5
10-1 ELECTRICAL CONTROL PANEL.................... 10-1 10-4 DRIVE MOTOR ................................................ 10-5
10-1.1 MAINTENANCE ...................................... 10-1 10-5 DEADMAN SWITCH ........................................ 10-5
10-1.2 CLEANING .............................................. 10-1
10-1.3 PANEL REMOVAL .................................. 10-1 11 OPTIONAL EQUIPMENT .......................................... 11-1
10-1.4 PANEL DISASSEMBLY .......................... 10-1 11-1 LOAD BACKREST ...........................................11-1
10-1.5 PANEL INSTALLATION .......................... 10-1
10-2 HORN REPLACEMENT................................... 10-1 12 ILLUSTRATED PARTS BREAKDOWN .................... 12-1
1-2 BL-PDSR 30-0319 - 03-07-2019

SECTION 1
DESCRIPTION
1-1. INTRODUCTION. forks raised or lowered; however, the speed is restri-

cted when the platform is raised above a preset limit.
.This publication describes the 24 volt lift truck distrib-
uted by Big Lift LLC. Included are operating instruc- The model number will be found on the name plate
tions, planned maintenance instructions, lubrication (Figure 1-1) along with the serial number, lifting capac-
procedures, corrective maintenance procedures and a ity, and load center. Figure 1-2 shows the locations of
complete parts list with part location illustrations. the truck's main components and controls.
Users shall comply with all requirements indicated in
applicable OSHA standards and current edition of
A.N.S.I. B56.1 Part II.By following these requirements
and the recommendations contained in this manual,
you will receive many years of dependable service
from your PDSR lift truck
The model number will be found on the name plate

(Figure 1-1) along with the serial number, lifting capac-
ity, and load center. Figure 1-2 shows the locations of
the trucks main components and controls.
1-2. GENERAL DESCRIPTION.

The self-propelled truck, (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 and turning is controlled by the steering
arm.Lift and Lower is controlled by pushbuttons on the
control head. The battery powered lift truck is quiet
and without exhaust fumes.
R6209
The reversible AC motor propels the lift truck in for-
Figure 1-1 Name Plate
ward or reverse direction throughout the available
speed range. The PDSR lift truck can be driven with
BL-PDSR 30-0319 - 03-07-2019 1-1

1-3. SAFETY FEATURES. • Separately fused control circuits and power circuits.
The PDSR is designed engineered to provide maxi- • Readily accessible horn button.
mum safety for operator and payload. Some of the
• Lift carriage backrest to help stabilize the load.
safety features incorporated into the design are:
• Handle to provide a firm hand hold for operator.
• Dead-man brake to apply the brake and cut off drive
power when the steering arm is released. • Flow control valve regulates maximum lowering
speed within prescribed limits.
• Belly-button switch to reverse truck should the oper-
ator accidentally pin himself against a wall or • Relief valve maintains hydraulic pressure within pre-
obstruction when backing up in slow speed. scribed limits.
• High speed limit switch to restrict speed when lift • High visibility color scheme of truck provides visual
carriage is raised above the preset limit. alert of truck's presence.
• All control functions automatically return to "OFF" • Battery Indicator.
when released. • Stabilizers.
• Externally accessible battery disconnect within oper-
ator's reach.
1-2 BL-PDSR 30-0319 - 03-07-2019

R3930
Figure 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
BL-PDSR 30-0319 - 03-07-2019 1-3

NOTES
1-4 BL-PDSR 30-0319 - 03-07-2019

SECTION 2
OPERATION
2-1. GENERAL. • Avoid overhead wires and obstructions.

This section gives detailed operating instructions for • Check for obstructions when raising or lowering the
the lift truck. The instructions are divided into the vari- lift carriage.
ous phases of operations, such as operating lift, driv- • Do not handle unstable or loosely stacked loads.
ing, and stopping. Routine precautions are included Use special care when handling long, high, or wide
for safe operation loads to avoid tipping, loss of load, or striking bysta-
nders.
2-2. OPERATING PRECAUTIONS.
• Center and carry the load as far back as possible
WARNING: Improper operation of the lift truck may toward the lift carriage back rest. The center-of-
result in operator injury, or load and/or lift gravity of the load must not exceed the load center
truck damage. Observe the following listed on the nameplate. See Figure 2-1 for load cen-
precautions when operating the lift truck. ter limitations.
The following safety precautions must be adhered to • Pick up loads on both forks. Do not pick up on only
at all times. one fork.
• Do not operate this truck unless you have been • When traveling, always lower the load as far as pos-
trained and authorized to do so. sible.
• All warnings and instructions must be read and • When stacking pallets in racks and it is necessary to
understood before using the equipment. move the load in a raised position, use caution.
Operate truck smoothly.
• Equipment must not be altered in any way.
• Observe applicable traffic regulations. Yield right of
• Equipment must be inspected by a qualified person
way to pedestrians. Slow down and sound horn at
on a regular basis.
cross aisles and wherever vision is obstructed.
• Do not exceed the rated capacity. Overloading may
• Operate truck only from designated operation posi-
result in damage to the hydraulic system and struc-
tion.Never place any part of your body between the
tural components.
mast uprights. Do not carry passengers.
• Be certain that the lifting mechanism is operating
• Do not allow anyone to stand or pass under load or
smoothly throughout its entire height, both empty
lifting mechanism.
and loaded.
• When leaving truck, neutralize travel control. Fully
• Be sure that mast is vertical - do not operate on a
lower lifting mechanism and set brake. When leaving
side slope.
truck unattended, turn off key switch, remove key
• Be sure the truck has a firm and level footing. and disengage the emergency stop switch.
R3814
Figure 2-1 Load Center

BL-PDSR 30-0319 - 03-07-2019 2-1
2-3. BEFORE OPERATION CAUTION: A QUALIFIED SERVICE TECHNICIAN
should check the truck monthly for
Table 2-1 covers important inspection points on the
proper lubrication, proper fluid levels,
PDSR lift truck which should be checked prior to oper-
brake maintenance, motor maintenance
ation.Depending on use, some trucks may require
and other areas specified in the SEC-
additional checks.
TION 3.
Figure 2-2 shows a sample format for an Operator
Checklist, which can be modified as necessary to fit WARNING: If the truck is found to be unsafe and in
your operation. need of repair, or contributes to an
unsafe condition, report it immediately to
WARNING: Periodic maintenance of this truck by a the designated authority. Do not operate
UALIFIED TECHNICIAN is required. it until it has been restored to a safe
operating condition. Do not make any
unauthorized repairs or adjustments. All
service must be performed by a qualified
maintenance technician.
Table 2-1 Operator Checks
ITEM PROCEDURE ITEM PROCEDURE

Transmission and Check for signs of fluid leak- Check drive wheel for cracks
hydraulic systems. age. or damage. Move truck to
Wheels
Check for cracks and dam- check load for freedom of rota-
Forks age; and, that they are prop- tion.
erly secured. Check operation of lift and
Check that they are in place, Hydraulic controls lower to their maximum posi-
Chains, cables and secured correctly, functioning tions.
hoses properly and free of binding or Check that brakes actuate
damage. when steering arm is raised to
Brakes
Check that safety guards are in upright position, and when low-
Guards and load ered to horizontal position.
place, properly secured and
backrest Check that steering arm raises
not damaged. Deadman/ Parking
Check that warning labels, to upright position when
brake
Safety signs nameplate, etc., are in good released and brake applies.
condition and legible Check that emergency stop
Emergency Stop
Check that horn sounds when switch can be disengaged and
Horn Switch
operated reengaged.
Check for binding or looseness Battery charge Check the battery indicator.
Steering Allow for enough space to
in steering arm when steering.
Check that speed controls on operate truck in high speed.
control head operate in all High speed limit Elevate forks approximately
Travel controls speed ranges in forward and switch two feet, then test drive truck
reverse and that belly button to check if high speed is cut
switch functions. out
2-2 BL-PDSR 30-0319 - 03-07-2019

R3815
Figure 2-2 Sample of Operator Check List
BL-PDSR 30-0319 - 03-07-2019 2-3

2-4. GENERAL CONTROL OPERATION. 3. To move forward (with load in back), slowly press
the speed control forward. See Figure 2-3. Press
The speed control (See Figure 2-3) located on each
the forward speed control farther to increase
side of the control head provides fingertip control for
speed.
driving the truck. Rotate the control in the direction
you want to travel. The farther you rotate the control 4. To slow down or stop, release the speed control
from the neutral position, the faster the truck will and lower or raise the steering arm to the horizon-
travel. tal or vertical position. In those positions, the
brake engages, slowing 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.
R8120 If there is no hazard, brake moderately to avoid
Figure 2-3 Forward / Reverse Control moving the load.
The pushbutton switches (See Figure 2-4), located on There are four different ways to stop the truck:
the front of the control head activate the lift-lower con- 1. Plugging: This electrical braking function con-
trols and the horn. sists of rotating the speed control lever in the
opposite direction of travel and then releasing it
when the truck stops. Plugging is a convenient
way to slow down the truck during normal
operation. If the control is not released, the truck
will accelerate in the opposite direction.
2. Steering arm (See Figure 2-5): The brake is fully
applied by lowering or raising the steering arm.
(See Figure 2-5) All traction control power is shut
off when the brake is engaged. When the steering
arm is in the upright position, the brake acts as a
parking brake. Deadman braking occurs when the
R8121
handle is released and spring action raises steer-
ing arm to the upright position.
Figure 2-4 Pushbutton Switches
3. Emergency braking: Press the emergency
brake switch, all electrical functions are cut out
2-5. DRIVING AND STOPPING PROCEDURES
and the truck automatically brakes.
1. Connect the battery and turn on the key switch.
4. Regenerative braking: If the speed control lever
Grasp the grips of the steering head so that the
is released, the truck automatically brakes regen-
speed control can be comfortably operated by
eratively.When the speed is below.5 MPH, the
either thumb.
brake applies.
2. Lower the steering arm to a comfortable position
above horizontal to disengage the brake and to
energize the electrical circuits. If the truck is not
moved, the electrical circuits will time out and will
deenergize. See.
2-4 BL-PDSR 30-0319 - 03-07-2019

2-7. STEERING ARM GAS SPRING
The steering arm gas spring automatically raises the
steering arm to the upright position when the
steering arm is released. If the steering arm does not
return fully, the steering arm gas spring requires
replacement.Return truck to maintenance for repair.
2-8. LIFT AND LOWER CONTROLS

Lift/Lower 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
R8122 pallet or skid, and the load is centered over the
forks and as far back as possible.
Figure 2-5 Brake Actuation 3. Raise forks to lift load.
4. Drive to area where load is to be placed.
2-6. BELLY-BUTTON SWITCH
5. Move truck to align load with its new position.
The belly-button switch (Figure 2-6) minimizes the
possibility of the driver being pinned by the steering 6. Lower the load until it rests squarely in place and
arm while driving the lift truck in slow speed. If the the forks are free.
switch presses against the operator while the lift 7. Slowly move the truck out from under the load.
truck is being driven toward the operator, the switch
changes the direction of the lift truck. 2-10. PARKING
When finished with moving loads, return the truck
to its maintenance or storage area. Turn off the key
switch and disconnect the battery. Charge battery as
necessary. Refer to battery care instructions, SEC-
TION 3.
R8123
Figure 2-6 Belly Button Switch
BL-PDSR 30-0319 - 03-07-2019 2-5

NOTES
2-6 BL-PDSR 30-0319 - 03-07-2019

SECTION 3
PLANNED MAINTENANCE
3-1. GENERAL. CAUTION: Gases produced by a battery can be

explosive. Do not smoke, use an open
Planned maintenance consists of periodic visual and
flame, create an arc or sparks in the
operational checks, parts inspection, lubrication, and
vicinity of the battery. Ventilate an
scheduled maintenance designed to prevent or
enclosed area well when charging.
discover malfunctions and defective parts. The
operator performs the checks in SECTION 2, and CAUTION: Batteries contain sulfuric acid which may
refers any required servicing to a qualified mainte- cause severe burns. Avoid contact with
nance technician who performs the scheduled mainte- eyes, skin or clothing. In case of contact,
nance and any required servicing. flush immediately and thoroughly with
clean water. Obtain medical attention
3-2. MONTHLY AND QUARTERLY CHECKS when eyes are affected. A baking soda
Table 3-1 is a monthly and quarterly inspection and solution (one pound to one gallon of wat-
service chart based on normal usage of equipment er) applied to spilled acid until bubbling
eight hours per day, five days per week. If the lift stops, neutralizes the acid for safe hand-
truck is used in excess of forty hours per week, ing and disposal.
the frequency of inspection and service should be
Leakage voltage from battery terminals to battery
increased accordingly. These procedures must be
performed by a qualified service technician or your case can cause misleading trouble symptoms with
EP Service Representative. the truck electrical system. Since components of
the truck electrical system are insulated from truck
3-3. BATTERY CARE frame, leakage voltage will not normally affect truck
operation unless a short circuit or breakdown of
3-3.1. General circuit wire insulation to truck frame occurs.
The PDSR may be equipped with maintenance free A voltage check from battery connector terminal
or industrial wet cell batteries. to battery case should indicate near zero volts.
Typically, however, the sum of the voltages at both
The care and maintenance of the battery is very
terminals will equal battery volts. This leakage
important to obtain efficient truck operation and voltage will discharge the battery. As battery
maximum battery life. cleanliness deteriorates, the usable charge of the
battery decreases due to this self discharge.
Although a leakage voltage reading of zero volts
may not be possible, a cleaner battery will have
more usable charge for truck operation and not affect
operation of electronic devices on the unit.
Table 3-1 Monthly and Quarterly Inspection and Service Chart
VISUAL CHECKS
INTERVAL INSPECTION OR SERVICE
Monthly Check electrical brake for proper operation.
Check load wheels for wear. A poly load wheel must be replaced if worn to within 1/16 inch
Monthly
of hub. Check for separation from hub.
Check drive wheel for wear. A poly drive wheel must be replaced if worn to within 3/4 inch
Monthly
of hub. Check for separation from hub.
Monthly Inspect wiring for loose connections and damaged insulation.
Monthly Inspect contractors for proper operation.
Monthly Check deadman brake switch for proper operation.
Monthly Check lift chain tension, lubrication & operation (see paragraph 3-6.)
Quarterly Check lift cylinder for leakage.
Quarterly Check for excessive jerking of steering arm when stopping or starting.
Semi-annually Inspect for chain wear (See SECTION 8)
BL-PDSR 30-0319 - 03-01-2019 3-1

3-3.2. Safety Rules 3. Before disconnecting or connecting batteries to a
charger, make sure the charger is “OFF”. If an
• Wear protective clothing, such as rubber apron,
attempt is made to do this while the charger is
gloves, boots and goggles when performing any
“ON”, serious injury to you, the battery and the
maintenance on batteries. Do not allow electrolyte
charger could result.
to come in contact with eyes, skin, clothing or floor. If
electrolyte comes in contact with eyes, flush 4. Before connecting the battery cable to the trucks
immediately and thoroughly with clean water. receptacle, make sure the key switch is off. The
Obtain medical attention immediately. Should battery cable must be fully connected before the
electrolyte be spilled on skin, rinse promptly with truck is used. If the plug is not making good con-
clean water and wash with soap. A baking soda tact, heat will weld the two parts of the battery
solution (one pound to one gallon of water) will connector together, making it difficult to remove
neutralize acid spilled on clothing, floor or any and necessary to replace.
other surface. Apply solution until bubbing stops 5. Battery terminals should be checked and cleaned
and rinse with clean water. of corrosion regularly. Good battery terminal con-
• If truck is equipped with wet cell batteries, keep vent tact is essential not only for operation, but also for
plugs firmly in place at all times except when adding proper charging of the battery.
water or taking hydrometer readings. Do not allow 6. The charging requirements will vary depending on
dirt, cleaning solution or other foreign material to the use of the truck. The battery should be given
enter cells. Impurities in electrolyte has a neutraliz- as equalizing charge on a weekly basis. This
ing effect reducing available charge. charge should normally be an additional three
• Do not bring any type of flame, spark, etc., near the hours at the finish rate.
battery. Gas formed while the battery is charging, is 7. Make certain battery used meets weight and size
highly explosive. This gas remains in cell long after requirements of truck. NEVER operate truck with
charging has stopped. an undersized battery.
• Do not lay metallic or conductive objects on battery. 3-3.4. Battery Cleaning
Arcing will result.
• Do not touch non-insulated parts of DC output Always keep vent plugs tightly in place when
connector or battery terminals to avoid possible cleaning battery. When properly watered and
electrical shock. charged, the battery will remain clean and dry. All
that is necessary is to brush or blow off any dust
• De-energize all AC and DC power connections
before servicing battery. or dirt that may accumulate on them. However,
• Do not charge a frozen battery. if electrolyte is spilled or overflows from a cell, it

should be neutralized with a solution of baking soda
• Do not use charger if it has been dropped or other- and water, brushing the soda solution beneath the
wise damaged. connectors and removing grime from the covers.
Then rinse the battery with cool water from a low
3-3.3. Battery Care and Charging pressure supply to remove the soda and loosen dirt. If
CAUTION: Never smoke or bring open flame near batteries stay wet consistently, they may be either
the battery. Gas formed during charging overcharged or over filled. This condition should be
is highly explosive and can cause seri- investigated and corrected.
ous injury.
1. Charge the battery only in areas designated for

that use.
2. Make certain the charger being used matches the
voltage and amperage of the truck battery.
3-2 BL-PDSR 30-0319 - 03-01-2019

3-4. CHARGING BATTERIES 3-5. LUBRICATION
Charging requirements will vary depending on depth Refer to Table 3-2 for the recommended types of
of discharge and temperature. Follow safety rules grease and oil. Table 3-3 in conjunction with Figure
when placing a battery on charge. 3-1 identifies the items requiring lubrication.
Proceed as follows:
3-6. LIFT CHAIN MAINTENANCE
1. Park truck at charging station with carriage low-
ered and turn the key switch off. Fully raise and lower lift carriage while observing
chains as they move over chain sheaves. Ensure
2. Check the condition of the AC cord and battery chain is aligned and tracking properly and all links
cables. If there are any cuts in the cable, any are pivoting freely. With lift carriage fully lowered,
exposed wires, loose plugs or connectors, DO spray or brush on a film of SAE 30 or 40 engine oil
NOT attempt to charge the batteries. Contact
appropriate personnel for repairs to be made.
3. Disconnect the batteries from the truck and con-
nect the batteries to the charger. Make sure
connectors are mated properly.
4. Connect the charger to the appropriate power
supply.
5. Follow the instructions for the charger being used.
Table 3-2 Recommended Lubricants (See Table 3-3 for Application)

No. 1 Transmission oil- 85W-90
Transmission oil-10W-30 (NOTE)
No. 2 Grease-Lithium base, general purpose.
No. 3 Hydraulic oil-Heavy duty with a viscosity of 150 SUS foam suppressing agent and rust and
oxidation inhibitors
Hydraulic oil-Heavy duty with a viscosity of 100 SUS foam suppressing agent and rust and
oxidation inhibitors (NOTE)
No. 4 SAE 30 or 40 Engine lubricating oil.
NOTE: USED ON COLD CONDITIONED TRUCKS
BL-PDSR 30-0319 - 03-01-2019 3-3

R8124
Figure 3-1 Lubrication Diagram

Table 3-3 Lubrication Chart
Method of TYPE
Pos. Location APPLICATION OF LUBRICANT
Application (Table3-2)
1 Transmission Capacity - 1.75 Liters Can No. 1 Fill to level plug opening.
Full length of channel where rollers

2 Inner & Outer Mast Brush No.2
operate.
Hydraulic Reservoir:
With lift carriage fully lowered, fill res-
Capacity - 13.78 Liters (L.H. 2600mm)
3 Can No. 3 ervoir with hydraulic oil to 1 inch
Capacity - 14.91 Liters (L.H. 3200mm)
below opening.
Capacity - 16.86 Liters (L.H.4000mm)
4 Lift Chain Brush or Spray No. 4 See Paragraph 3-6
3-4 BL-PDSR 30-0319 - 03-01-2019

SECTION 4
TROUBLESHOOTING
4-1. GENERAL Operate:

Use Table 4-1. as a guide to determine possible Truck Does Not Operate Forward or Reverse: Trouble
causes of trouble. The table is divided into five main With Braking: Trouble With Lifting Or Lowering, and
categories: Truck and Hydraulic System Will Not Miscellaneous malfunctions.
Table 4-1. Troubleshooting Chart
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

TRUCK AND HYDRAULIC
SYSTEM WILL NOT OPERATE
Check fuse and replace if neces-
a. Fuse blown.
sary.
Check fuse and replace if neces-
b. Fuse blown.
sary.
Check battery connections and
c. Battery dead or disconnected.
Truck will not travel not will lift sys- check battery voltage.
tem operate. Bypass key switch to determine if
d. Key switch defective
it is malfunctioning.
Bypass the switch to determine if it
e. Emergency brake switch defective.
is malfunctioning.
Check for open circuit. Repair as
f. Defective wiring.
required
TRUCK DOES NOT OPERATE
FORWARD OR REVERSE
a. Check all wiring. A loose connec-
Tighten all loose connections
tion may be the cause of mal-
before further troubleshooting.
function.
Truck does not travel forward or Check and replace switch if defec-
b. Defective deadman switch.
reverse. All other functions operate tive.
normally. Check for proper operation and
c. Defective main controller.
replace if necessary.
d. Defective potentiometer in control Check and replace potentiometer
head. if defective.
Truck travels forward but not in Defective potentiometer in control Check and replace potentiometer
reverse. head. if defective.
Truck travels reverse but not in Defective potentiometer in control Check and replace potentiometer
forward. head. if defective.
BL-PDSR 30-0319 - 03-07-2019 4-1

Truck travels forward and in reverse

Defective potentiometer in control Check and replace potentiometer
at lower speeds; will not travel at head. if defective.
high speed.
TROUBLE WITH BRAKING
Check deadman switch for conti-

nuity. If none found when the con-
Truck does not slow with brake, or a. Defective deadman switch.
trol arm is in the brake position,
brake does not engage. replace switch.
b. Defective electric brake. Adjust or replace brake.
a. Defective electric brake. Replace.
Brake will not release. b. Brake temperature above 281° F Allow to cool and check air gap.
c. Open brake circuitry or wiring. Make voltage checks.
Brake drags. Defective electric brake Replace.
a. Incorrect stopping distance adjust-
Adjust.
Brake grabs. ment
b. Defective electric brake. Replace.
Abnormal noise and chatter when
Defective electric brake Replace.
brake is applied.
TROUBLE WITH LIFTING OR
LOWERING
Oil sprays or flows from the top of
Defective packing in lift cylinder. Repair lift cylinder.
the lift cylinder.
a. Oil level too low. Identify oil leak and fill reservoir.
Squealing sounds when lifting forks.
b. Lift linkage binding. Apply grease.
a. Oil level too low. Add oil to reservoir.
Forks do not lift to top.
b. Load larger than capacity. Refer to I.D.plate for capacity.
Check pressure. Adjust as neces-
a. Defective pump or relief valve
sary.
b. Worn lift cylinder. Replace cylinder.
Weak, slow or uneven action of
hydraulic system. c. Load larger than capacity. Refer to I.D.platefor capacity.
d. Defective lift motor solenoid. Replace solenoid on pump motor.
e. Battery charge low. Charge battery.
4-2 BL-PDSR 30-0319 - 03-07-2019

a. Battery is dead or disconnected. Check and recharge if required.
b. Defective wiring. Check and repair as required.

Forks do not lift, pump motor does
not run.
c. Defect in electrical system for operat- Check lift switch in control head as
ing pump motor. well as the solenoid.
TROUBLE WITH LIFTING OR

LOWERING - Continued
Check the oil level in the reservoir
and the oil lines to the lift cylinder,
Forks do not lift, motor runs. Defect in hydraulic system. and repair as required. If normal,
check the hydraulic pump, and
relief valve. Repair, or adjust.
Check lowering control switch in
control head and lowering sole-
Forks lift, but will not go down. Defect in hydraulic system
noid on valve assembly. Replace
as required
a. Oil bypassing internally in control
Replace valve assembly.
Load will not hold. valve.
b. Worn lift cylinder or packing. Repack cylinder.
a. Oil level too low. Add oil to reservoir.
Refer to nameplate on side of
Forks does not lift to top. Pump b. Load larger than capacity.
mast for maximum load capacity.
motor runs
c. Incorrect stopping distance adjust-
Change batteries.
ment.
Check for leaking fitting in hydrau-
Forks creep downward under load Leak in hydraulic system, lift cylinder or lic line and repair as required.
when in a raised position. lowering valve. Repack lift cylinder or replace
valve assembly .
MISCELLANEOUS
a. Week return spring. Replace spring.
Steering arm does not return to the Check and free the binding item.
upright position. Verify that the cable has not been
b. Binding.
damaged. Repair or replace as
needed.
Check for short, and repair or
a. Belly-button switch defective.
replace as necessary.
Truck moves forward when arm is
pulled down. Check wiring and repair as
b. Short in control head. required. Check wiring and repair
as required.
Steering arm jerks excessively start- Replace drive wheel if worn to
Drive wheel worn.
ing or stopping the truck. within 3/4 inch of hub.
Drive motor is jerky. Motor internally damaged or worn. Replace motor.
BL-PDSR 30-0319 - 03-07-2019 4-3

4-2. CONTROLLER TROUBLESHOOTING 4-2.3 Testing Truck Operation
4-2.1 Zapi Handset (Optional) The Zapi Handset can be used to test certain truck
operations as follows:
A Zapi Handset is available that is designed specifi-
cally for use with the Zapi controller. It serves multiple 1. Connect the Zapi Handset, refer to paragraph 4-
functions of reading diagnostic data, testing truck 2.1
operation, setting options, adjustments and parameter 2. Press the ROLL down button and the ENTER
changes of the controller. The Zapi Handset is avail- button at the same time to enter the MAIN MENU.
able through your Big Lift LLC dealer. If you require 3. Press the ROLL down button or the ROLL up but-
dealer location information, contact Big Lift LLC. ton to find the TESTER display.
4-2.2 Fault Detection 4. Press the ENTER button to view the tests.
5. To verify various switch functions, locate the
4-2.2.1 General switch on the display and then operate that func-
The controller provides diagnostics information to tion to verify operation.
assist technicians in troubleshooting problems. When a 6. Press the OUT button to exit the tests.
fault is detected, an alarm is recorded in the log-
book.It has a FIFO (First Input First Output) structure
that means the oldest alarm is lost when the database
is full and a new alarm occurs.The logbook is com-
posed of alarms with the following information:
• The alarm code.
• The number of times that each alarm occurs con-
secutively.
• The Hour Meter reading (value) when the latest
event of every alarm occurred.
• The invert temperature when the latest event of
every alarm occurred.
This 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 button to view the alarms.
R8125
5. Press the OUT button to exit the alarms.
NOTE: Refer to bigjoesupport.com for the Zapi sup-

plement containing detailed information of Figure 4-1Hand Held Programmer
alarm codes. There are two versions shown.
The PDS uses the Standard version which
lists the error by: Alarm Name, Repetitions,
Temperature and Hour Meter reading.
4-4 BL-PDSR 30-0319 - 03-07-2019

4-2.4 Settings and Adjustments 4. Press the ENTER button to view the options.
5. Press the ROLL down or the ROLL up button to
4-2.4.1 Set Options find the option to be changed.
To set options proceed as follows and refer to 6. Press the SET up button or the SET down button
Table 4-2: (6) until the desired value setting is reached. The
option is now set at the desired value.
1. Connect the Zapi Handset, refer to paragraph
4-2.1. 7. Press the OUT button to exit the options.
2. Press the ROLL up button and the SET up button
(5) at the same time to enter the CONFIG MENU.
3. Press the ROLL down button or the ROLL up but-
ton to find the SET OPTIONS display.
Table 4-2Traction Controller
Error Message
Possible Cause Fault Elimination
Code Error Text
This is an error on the choice of the So ask for the assistance of a Zapi
99 SLIP PROFILE
parameters of the slip profile. technicians when this alarm
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
This alarm occurs when both the travel
failures.
80 FORW+BACK (Fwd and Rev) are active at the same
A failure in the logic is possible too. So,
time.
when you have verified the travel
demand switches and wiring are cor-
rect, it is necessary to replace the con-
troller.
The possible reasons for this alarm are
(use the readings in the TESTER to
facilitate the troubleshooting):
• A travel demand was active at key-on.
• Presence man sensor was active at
key- on.
INCORRECT This is a warning for an incorrect start-
79 Check the wiring. Check the micro-
START ing sequence.
switches. It could also be an error
sequence made by the operator. A fail-
ure in the logic is possible too; so when
all of the above are checked and noth-
ing was
found, replace the controller.
The test is made at key-on and after 20
sec that both the travel demands have
been turned off. This alarm occurs if the
Check the mechanical calibration and
78 VACC NOT OK ACCELERATOR reading in the TES-
the functionality of the potentiometer.
TER menu is 1.0V higher than PRO-
GRAM VACC min acquisition when the
accelerator is released.
BL-PDSR 30-0319 - 03-07-2019 4-5

Error Message
Code Error Text
This alarm occurs when the tempera-
Improve the air cooling of the controller.If
ture of the base plate is higher than
the alarm is signaled when the control-
85°C. Then the maximum current
ler is cold, the possible reasons are a
62 TH. PROTECTION decreases proportionally with the tem-
thermal sensor failure or a failure in the
perature increases from
logic card. In this case, it is necessary
85°C to 105°C. At 105°C the
to replace the controller.
Current is limited to 0 Amps.
Charge the battery.If charging does not
This occurs when the battery charge is help, using a voltmeter, measure the bat-
calculated being less than or equal to tery voltage and compare the reading
65 BATTERY LOW 10% of the full charge and the BAT- with the value in the BATTERY VOLT-
TERY CHECK setting is other than 0 AGE parameter. If they are different,
(refer to SET OPTION menu). adjust the value of the ADJUST BAT-
TERY function.
Try to execute a CLEAR EEPROM
operation (refer to CONSOLE manual).
This is due to a HW or SW defect of the Switch the key off and on to check the
non-volatile embedded memory sup- result. If the alarm occurs permanently,
porting the controller parameters. This it is necessary to replace the controller.
71 EEPROM KO
alarm does not inhibit the machine If the alarm disappears, the previously
operations, but the truck will work with stored parameters will have been
the default values. replaced by the default parameters.with
the temperature increases from 85°C to
105°C.
Check the thermal sensor inside the
motor (use the MOTOR TEMPERA-
This warning occurs when the tempera- TURE reading in the TESTER menu);
MOTOR ture sensor is opened (If digital) or has check the sensor ohmic value and sen-
65
TEMPERATURE overtaken the threshold of 150°C sor wiring. If the sensor is OK, improve
(if analog). the air cooling of the motor. If the warn-
ing is present when the motor is cool,
then the problem is inside the controller.
THERMIC The output of the controller thermal This type of fault is not related to exter-
61
SENSOR KO sensor is out of range. nal components; replace the controller.
It is just enough to turn the CHECK UP
CHECK UP This is just a warning to call for the time
DONE option to level ON after the
NEEDED programmed maintenance.
maintenance is executed.
DATA The alarm ends when the acquisition is
Acquisition of the current gains.
ACQUISITION done.
4-6 BL-PDSR 30-0319 - 03-07-2019

Error Message
Code Error Text
The SW continuously checks for the
connection of the two supply ends of
the potentiometer
in the accelerator. The test consists of
reading the voltage drop on a sense
diode, connected between NPOT
(CNA#30) and GND and cascaded with
the potentiometer:
if the potentiometer gets disconnected Check the Voltage on NPOT and the
86 PEDAL WIRE KO
on PPOT (NNA#25) or NPOT, no cur- poten- tiometer connections.
rent flows in
the sense diode and the voltage on the
NPOT connection collapses down.
When the NPOT voltage is less than
0.3V this alarm occurs. This alarm also
occurs when the NPOT voltage is
higher than 2Vdc (to detect the condi-
tion of a broken sense diode).
Warning: When the tiller is released,
At the next travel request, the warning
51 TILLER OPEN after a fixed period of time of standby
will disappear.
(30 seconds) the main contactor open.
The Maximum current gain parameter
are at the default values, which means Ask the assistance of a Zapi technician
92 CURRENT GAIN the maximum current adjustment pro- to do the correct adjustment procedure
cedure has not been carried of the current gain parameters.
out yet.
The controller receives from the CAN
the message that another controller in
the net is in fault condition; as a conse-
WAITING FOR quence
68 NODE the ACOE controller itself cannot enter
an operative status,
but has to WAIT for the other controller
coming out from the fault status.
• If the fault is present at start up, it is
very likely that the hw over current pro-
tection circuit is damaged, it is neces-
VALVE COIL This alarm occurs when there is a short
76 sary to replace the controller.
SHORTED circuit on an on/off valve coil.
• If the fault is present when the control-
ler drives the outputs, the problem is
located in the harness and in the coils.
Check if there is a short or a low imped-
ance between the negative of one of
EV1 DRIVER
74 Electro valve EV1 driver is shorted. these coils and -BAT. Otherwise the
SHORTED
driver circuit is damaged and the con-
troller must be replaced.
BL-PDSR 30-0319 - 03-07-2019 4-7

Error Message
Code Error Text
ance between the negative of this coil
and -BAT. This warning also occurs if
the external load is not present and the
EV2 DRIVER parameter EV2 in the “Set Options”
74 Electro valve EV2 driver is shorted
SHORTED menu is set “PRESENT”, in this case
the warning disappears setting the EV2
parameter “ADBSENT”. Otherwise the
driver circuit is damaged
and the controller must be replaced.
ance between the negative of this coil
and -BAT. This warning also occurs if
the external load is not present and the
EV3 DRIVER parameter EV3 in the “Set Options”
74 Electro valve EV3 driver is shorted
SHORTED menu is set “PRESENT”, in this case
the warning disappears setting the EV3
parameter “ADBSENT”. Otherwise the
driver circuit is damaged
and the controller must be replaced.
In standby condition (pump motor not
driven), the feedback coming from the This type of fault is not related to exter-
56 PUMP I NO ZERO
current sensor in the pump chopper nal components; replace the controller.
gives a value out of a permitted range.
• Check the motor connection, that
there is continuity. If the motor connec-
This test is carried out when the pump
tion is opened, the current cannot flow,
motor is running, and it verifies that the
so the test fails and the error code is
52 PUMP I=0 EVER current feedback sensor is not con-
displayed.
stantly
• If everything is ok for what it concerns
stuck to 0.
the motor, the problem could be in the
current sensor or in the related circuit.
The EV1 valve driver is not able to drive The device or its driving circuit is dam-
75 CONT. DRV. EV1
the load (cannot close). aged, replace the controller.
75 CONT. DRV. EV2
75 CONT. DRV. EV3
PUMP VACC NOT The minimum of the lift potentiometer is It is suggested to repeat a “PROGRAM
89
OK not correctly set. VACC” procedure
• Check the correct connection of the
• The motor temperature sensor is not motor temperature sensor.
SENS. MOT. TEMP. correctly connected to A22. • If the current sensor is correctly con-
67
KO • The motor temperature sensor is nected, replace it.
damaged. • If the problem persist, replace the
controller.
Please re-acquire the VACC parame-
The voltage on CNC#4 is outside of the
85 VACC OUT RANGE ters with a PROGRAM VACC proce-
parameters’ range.
dure.
4-8 BL-PDSR 30-0319 - 03-07-2019

Error Message
Code Error Text
Please check if the sign of FRE-
The traction rotor is stuck or the
QUENCY and ENCODER on the tester
11 STALL ROTOR encoder signal is not correctly received
menu are the same and different than
by the controller.
zero during a traction request.
Please check the EVP coil impedance.
EVP DRIVER The EVP driver is damaged or the EVP
48 If the EVP impedance is OK, the prob-
OPEN coil impedance is too law.
lem is inside the controller.
Just one pump function at a time can be
MANY PUMP More than one pump functions were
49 requested. Please reset all the requests
REQS requested at the same time
and try again.
The possible reasons for this alarm are:
• Pump request active at key-on.
• Pump request active without man
presence.
Check the wirings. Check the micro-
This is a warning for a pump incorrect switches. It could also be an error
79 PUMP INC START
starting sequence. 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.
If the EVP TYPE parameter is set to
ANALOG, please acquire again the val-
ues of MIN LOWER and MAX LOWER.
PUMP VACC The voltage on CNC#9 is outside of the If the controller is in Combiacx configu-
90
RANGE parameters range. ration and the PROPORTION. LIFT
parameter
is set to ON, please acquire again also
the values of MIN LIFT and MAX LIFT.
If a CLEAR EEPROM was mode before
the last key on-recycle, this warning just
means that the EEPROM was correctly
cleared. A travel demand or a pump
This warning appears when the control-
13 PARAM RESTORE request cancel the alarm.
ler restored the default values.
If this alarm appears at key on without
any CLEAR EEPROM request by the
operator, there could be a problem
inside the controller.
BL-PDSR 30-0319 - 03-07-2019 4-9

Table 4-3 Steering Controller
Error Message
Code Error Text
Main uC and slave uC communicate
via a local serial interface. This
alarm occurs when the slave uC
6 SERIAL ERR #1 It is necessary to replace the controller.
does not receive the communica-
tion from the main uC through this
serial interface.
It occurs if a test to write and read
one location in EEPROM fails.
The SW expects to read the
written value.
It also occurs when the hour
13 EEPROM KO meter gives different values It is necessary to replace the controller.
between the three redundant
locations in which it is
recorded.
It also occurs when the busy bit of
the EEPROM does not rise
within 12 msec.
LOGIC FAILURE #4 This alarm occurs in the rest state if
the output of the voltage amplifier of
16 It is necessary to replace the controller.
the phase Vw-Vv have a drift larger
than ±0.25 V
LOGIC FAILURE #3 This alarm occurs in the rest state if
the output of the voltage amplifier of
17 It is necessary to replace the controller.
the phase Vu-Vw have a drift larger
than ±0.25 V.
LOGIC FAILURE #2 This alarm occurs when the real
18 voltage between phases W It is necessary to replace the controller.
and V of the motor is different from
the desired voltage.
LOGIC FAILURE #1 This alarm occurs when the real
19 voltage between phases W It is necessary to replace the controller.
and U of the motor is different from
the desired voltage.
This alarm occurs in the initial rest
state after key-on it the inputs
32 VMN NOT OK of motor voltage amplifiers are It is necessary to replace the controller.
not in the window from 2.2 to
2.8 Vdc.
This alarm occurs only when the
setting CAN BUS is PRESENT.
Then the EPS-AC0 waits for a
via CAN information that the Find, on the traction controller, the rea-
48 MAIN CONT. OPEN traction controller has closed the son for keeping the main contactor
open.
main contactor. If this information
lacks more than about
1.5 secs, this alarm occurs.
4-10 BL-PDSR 30-0319 - 03-07-2019

Error Message
Code Error Text
This alarm occurs two ways:
1) In the initial rest state after key-
on, if the outputs of the current
amplifiers are not comprised in the
53 STBY I HIGH window 2.2 to 2.8 Vdc. It is necessary to replace the controller.
2) After the initial diagnosis this
alarm occurs when the outputs of
the current amplifiers at rest have a
drift larger than ±0.15V.
This alarm occurs if the tempera- Improve the cooling of the controller;
61 HIGH TEMPERATURE ture of the controller base plate otherwise it is necessary to replace the
overtakes 75 degrees. controller.
This alarm occurs only when DIA
MOTOR TEMP is on and the thermal
sensor inside the
motor measures a temperature
Check that the thermal sensor in the
MOTOR higher than 150 degrees. It
65 motor is working correctly. If it is,
TEMPERATURE also occurs when trying to acquire
improve the cooling of the motor.
the motor resistance with a tempera-
ture in the motor higher than 150
degree (still with DIAG MOTOR
TEMP to ON).
This alarm occurs if the circuit to
Check the motor is suited to work with
limit via hardware the current in the
the EPS-DC0 (not oversized). Other-
70 HIGH CURRENT motor is either always
wise it is necessary to replace the con-
active at key-on or repeatedly active
troller.
when the motor is turning.
Check the power fuse is OK. Check the
This alarm occurs when the current
battery positive arrives to the controller.
in the phase V of the
71 POWER FAILURE #3 Check the continuity of the wire in the
motor is zero and the motor is com-
phase V of the motor. Otherwise it is
manded for moving.
necessary to replace the controller.
in the phase U of the
motor is zero and the motor is com-
phase U of the motor. Otherwise it is
manded for moving.
in the phase W of the motor is zero
and the motor is commanded for
phase W of the motor. Otherwise it is
moving.
It occurs in applications with toggle
switches when the applied fre-
Swap in between two encoder channels
83 BAD ENCODER SIGN quency (FREQUENCY) and motor
(CNB#7 with CNB#8).
sped (ENC SPEED)
have opposite sign.
BL-PDSR 30-0319 - 03-07-2019 4-11

Error Message
Code Error Text
This alarm occurs if the command
potentiometer (CPOC1 on CNA#9 or
CPOC2 on CNA#8) changes with a
84 STEER SENSOR KO jerk larger than MAX SP SLOPE. Change the steer pot.
This alarm is used to catch a discon-
tinuity in the voltages of the com-
mand potentiometer.
This is just a warning to inform that
the steering controller is limiting the
85 STEER HAZARD angle in the steering direction. No
speed reduction occurs on the trac-
tion.
The main uC sends an analog signal
towards the slave uC to reset the
slave uC on demand. When the
slave uC detects the analog signal
218 CLOCK PAL NOT OK It is necessary to replace the controller.
external to a window from 2.2 to 2.8
and not in the range to generate the
reset on demand, the slave uC
raises this alarm.
When the safety contacts are open, the
voltage on CNA#4 is expected to be
close to 0 Vdc and this is independent
from whether the safety contacts are
It occurs when the voltage on
connected to a plus battery or to a
CNA#4 (NK1: Lower Potential Termi-
minus battery. In the first case (safety
99 INPUT ERROR #1 nal of the Safety Contacts) is higher
contacts connected
than 12 V before to turn the safety
to a plus battery), when the safety con-
contacts closed.
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.
It occurs when the encoder counting
212 MICRO SLAVE #8 of the main uC is not matched with It is necessary to replace the controller.
the encoder counting the slave uC.
This alarm occurs if the frequency
and the amplitude of the voltages
from the stepper motor lines are
STEPPER MOTOR mismatched in
219 between. In normal condition when It is necessary to replace the controller.
MISM
the amplitude of the stepper motor
lines increases, the frequency of the
stepper motor lines must increase
too.
This alarm occurs if the current in
Search for a mechanical problem lock-
220 MOTOR LOCKED the steering motor stays close ing the motor. To help in the fault find-
to the maximum current longer tan 1 ing, set DEBUG OUTPUT to level 11.
sec.
4-12 BL-PDSR 30-0319 - 03-07-2019

Error Message
Code Error Text
It occurs in one or the following con-
ditions:
(Open loop application only) If the
slave uC detects the stator voltage
phase rotates in the opposite direc-
tion respect to
221 MICRO SLAVE #4 It is necessary to replace the controller.
the sign of the stepper motor speed.
(Closed loop application only) If the
slave uC detects the stator voltage
phase rotates in the opposite direc-
tion respect to the commanded posi-
tion.
In application with a feedback poten-
tiometer, this alarm occurs if the In application with the feedback potenti-
feedback potentiometer (CPOT on ometer, verify potentiometer is not
CNB#6) does not change (or mechanically loosened. Check there is
changes in the opposite direction) its not a mechanical block of the steered
value even if commanded to wheel. Be sure the wiper has not
222 FB POT LOCKED change. reached its own electrical limit because
In application with toggle switches of too much angle of the steered wheel.
with ENCODER CONTROL to Besides, this alarm may occur at the
off, this alarm occurs if the feedback installation when the motor rotates in
encoder counting does not change the wrong direction turning away from
its value even if commanded to the desired direction.
change.
This alarm occurs if the feedback
potentiometer (CPOT on CNB#6)
changes with a jerk larger than 0.3V
223 JERKING FB POT Change the feedback potentiometer.
in 16 msec. This alarm is used to
catch a discontinuity in the voltages
of the feedback potentiometer.
This alarm occurs when the parame-
ter to compensate for the gain of the It is necessary to send the controller to
225 CURRENT GAIN current amplifiers (ADJUSTMENT Zapi to perform, the maximum current
#03 and ADJUSTMENT #04) have regulation.
the default values.
Every 16msec, inside the code
cycle, the main uC rises and then
lowers an input for the slave uC
(SYNC). When the slave uC detects
no edge for more than 100 msec on
226 NO SYNC this input, this alarm occurs. This is It is necessary to replace the controller.
just a watch dog function:
when the main uC does not execute
the code cycle it does not update the
SYNC signal and the slave uC cuts
off the steer and traction.
BL-PDSR 30-0319 - 03-07-2019 4-13

Error Message
Code Error Text
Main uC and Save Uc communicate
via a local serial interface. This
alarm occurs when the main uC
227 SLAVE COM. ERROR It is necessary to replace the controller.
does not receive the communica-
tion from the slave uC through this
serial interface.
This warning occurs only if CAN
BUS is PRESENT. At key-on the
EPS-AC0 asks the traction controller
to send a list of parameters via CAN
BUS. From the request until the
237 WAITING DATA
parameter are correctly received,
this warning occurs. The steer is not
activated yet, and the safety relays
remain open when this warning is
present.
Check the potentiometer connected to
CNB#6 is working correctly. If toggle
switches are connected to CNA#2 and
CNA#3, verify they are working cor-
rectly and the setting AUX FUNCTION
This alarm occurs for a error in the 11 is correct. Verify that sensor bearing
228 POSITION ERROR redundant test of the feedback in the motor (encoder) has not slipped
sensors. (the sensor 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.
This is a real alarm that cuts off the
traction. It occurs at the initial align-
ment if the straight ahead condition
238 EPS NOT ALIGNED is not matched within 6 sec.
Throughout the 6 sec delay, steering
is not activated, the safety relays are
open and the traction is stopped.
At key-on the EPS-AC0 needs an
assent from the traction controller to
close the safety contacts and to turn
on the operational mode. Until this
239 WAITING FOR TRAC
happens, this warning occurs.The
steer is not activated and the safety
relays remain open when this warn-
ing is present.
This condition is several times due to
either, a mismatching between the
It occurs when ENCODER CON-
Encoder resolution used in the SW and
TROL is set ON and the real fre-
241 ENCODER ERROR the real encoder resolution, or a wrong
quency does not pursuit the com-
connection between the two encoder
manded frequency.
channels. In this latest case, exchange
the connections.
4-14 BL-PDSR 30-0319 - 03-07-2019

Error Message
Code Error Text
This alarm occurs when the mean Check the continuity of the stepper
voltage of the Quadrature line motor connections. In particular the
of the stepper motor (connection resistance between CNA#8 and the
242 Q LINE SENSOR KO
CNA#8) is not null: the voltage on negative battery (with the stepper motor
every stepper motor line is a sine at rest) is expected to be very low
wave with null mean voltage. (close to 30 ohms).
This alarm occurs when the mean Check the continuity of the stepper
voltage of the Direct line of the step- motor connections. In particular the
per motor (connection CNA#9) is not resistance between CNA#9 and the
243 D LINE SENSOR KO
null: the voltage on every stepper negative battery (with the stepper motor
motor line is a sine wave with null at rest) is expected to be very low
mean voltage (close to 30 ohms).
The parameters to compensate for
the gain of the current amplifiers
(ADJUSTMENT #03 and ADJUST-
MENT #04 are recorded in a not vol-
It is necessary to send the controller to
atile memory (eeprom) with a
244 GAIN EEPROM KO Zapi to execute the maximum current
redundant handling. In fact every
regulation.
adjustment is recorded in three
eeprom locations. If the values in
these thee location are different,
this alarm occurs.
This alarm occurs when acquiring
the motor resistance or when adjust-
245 DATA ACQUISITION ing the parameters to compensate Recycle the key.
for the gain of the current amplifiers
(maximum current factory adjusted).
In stepper motor application, this
alarm occurs if the main uC is
detecting a direction of the stepper
motor not matched
with the one that the slave uC
is detecting.
In closed loop application, this alarm
246 MICRO SLAVE KO occurs if the main uC is detecting a It is necessary to replace the controller.
direction of the steering error not
matched with the one that the slave
uC is detecting.
Furthermore, this alarm occurs if the
main uC is detecting no steering lim-
itation meanwhile the slave uC is
detecting a steering limitation.
This alarm occurs only when the set-
ting CAN BUS is PRESENT. Then
Check the CAN Bus communication
the EPS-AC0 must receive the
system and analyse the frames from
247 CAN BUS KO event messages from the traction
the traction controller to the steer con-
controller. If these messages lack
trollers.
more than about 1 sec, this alarm
occurs.
BL-PDSR 30-0319 - 03-07-2019 4-15

Error Message
Code Error Text
This alarm occurs for a fault on the
command potentiometer (CPOC2on
CNA#8). When a single command
pot is chosen, the alarm occurs if the
Check the connections of the potenti-
wiper (CPOC1) exits the range from
ometer. This alarm occurs when one
248 S.P OUT OF RANGE 0.8 Vdc to 4.2 Vdc. When the twin
connection of the command potentiom-
pot is chosen, the alarm occurs if the
eter is broken.
sum of the two wiper voltages
(CPOC1 + CPOC2) exists the range
from
4.5 Vdc to 5.5 Vdc.
This alarm occurs for a fault on the
Check the connections of the feedback
feedback potentiometer (CPOT on
potentiomerter. This alarm occurs when
249 F.B OUT OF RANGE CNB#6). This alarm occurs in CPOT
one connection of the feedback poten-
exits the range from 0.3 Vdc to 4.7
tiometer is broken.
Vdc.
It occurs when the information on
the status bus between the
250 MICRO SLAVE main uC and the slave uC is frozen It is necessary to replace the controller.
to the OFF value (the slave uC does
not update the status bus configura-
tion).
This alarm occurs if the slave uC
detects the safety contact, of the
251 KM OPEN It is necessary to replace the controller.
main uC, o[pen when expected
being closed.
This alarm occurs if the slave uC
252 KS OPEN It is necessary to replace the controller.
main uC, open when expected being
closed.
This alarm occurs if the connection
CNA#5 (K1) is around a voltage of 12
This alarm occurs at key-on if the
Vdc when switching on the key. In fact,
slave uC detects the safety contact,
253 KM CLOSED when the safety contacts are open, K1
of the main uC, closed prior to being
is expected to be plus battery voltage
commanded.
(not 12 V). Search for a harness prob-
lem or replace the controller.
This alarm occurs if the connection
CNA#4 (NK1) is around a voltage of 12
This alarm occurs if the main uC
Vdc when switching on the key. In fact,
254 KS CLOSED when the safety contacts are open,
slave uC, closed prior to being com-
NK1 is expected to be a minus battery
manded.
voltage (not 12 V). Search for a harness
problem or replace the controller.
4-16 BL-PDSR 30-0319 - 03-07-2019

R8126
Figure 4-2 Wiring Diagram
BL-PDSR 30-0319 - 03-07-2019 4-17

NOTES
4-18 BL-PDSR 30-0319 - 03-07-2019

SECTION 5
OPERATING CONTROL SYSTEM
5-1. CONTROL HEAD 4. Remove screw, washer and control knob from
other side of potentiometer.
5-1.1 Cap Assembly Removal
5. Remove potentiometer from cover.
1. Engage the emergency stop switch and turn off
6. Position new potentiometer in cover.
key switch.
7. Install control knob on potentiometer and secure
2. Remove four screws, lift up cap and disconnect
with screw, and washer.
harness from harness.
8. Install control knob on the other side of poten-
5-1.2 Cap Assembly Installation tiometer and secure with screw and washer.
1. Hold up cap in place and connect harness to har- 9. Connect harness to potentiometer.
ness. 10. Install the up cap as described in paragraph 5-1.2.
2. Position up cap on control head and secure with
four screws. 5-1.6 Belly-Button Switch Replacement
3. Disengage the emergency stop switch and turn 1. Remove the up cap as described in paragraph
on key switch. 5-1.1.
2. Disconnect harness from reversing switch wiring.
5-1.3 Control Head Removal
3. Remove reversing switch from potentiometer.
1. Remove the up cap as described in paragraph
4. Position the new reversing switch in potentiome-
5-1.1. ter.
2. Disconnect harness from potentiometer and 5. Reconnect harness to reversing switch wiring.
switch. 6. Install the up cap as described in paragraph
3. Remove three screws, three lock washers and 5-1.2.
three flat washers.
WARNING: When removing the control head in the

following steps, be sure to hold it in place
until the control harness is disconnected.
4. Remove the control head and handle.
5-1.4 Control Head Installation

1. Hold control head and handle in place and install
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.
BL-PDSR 30-0319 - 03-07-2019 5-1

DR_0007
Figure 5-1 Control Head Assembly
5-2 BL-PDSR 30-0319 - 03-07-2019

DR_0006
Figure 5-2 Steering Arm
BL-PDSR 30-0319 - 03-07-2019 5-3

5-1.7 Horn Switch Replacement 5-3. STEERING ARM
1. Remove the up cap as described in paragraph 5-3.1 Return Spring Replacement
5-1.1.
The steering arm gas return spring is replaced while
2. Remove two screws, brackets and spring. the steering arm is in the upright position.
3. Remove the screw, bracket and horn wiring
from the up cap.
key switch.
4. Position the new horn wiring on the up cap and
2. Secure the steering arm in the upright position.
secure with screw and bracket.
3. Remove screw and free the gas return spring
5. Position horn switch in the up cap and secure
from bracket.
with two screws and brackets.
4. Pull downward on the gas return spring to free
6. Install the up cap as described in paragraph
it from its seat inside steering arm.
5-1.2.
5. Position the new gas return spring inside the
steering arm being sure it fully engages its seat.
5-1.8 Lift and Lower Switch Replacement
6. Position the opposite end of the gas return spring
1. Remove the up cap as described in paragraph on bracket and install screw.
5-1.1.
7. Disengage the emergency stop switch and turn
2. Disconnect harness from switch. on key switch
3. Remove switch form cap.
5-3.2 Steering Arm Removal
4. Position the new switch and Connect harness to
switch. 1. Engage the emergency stop switch and turn off
key switch.
5. Install the up cap as described in paragraph 5-
1.2. 2. Remove the return spring as described in para-
graph 5-3.1.
NOTE: Other switches replaced like this. 3. Disconnect harness from main harness.
5-2. COMPARTMENT COVERS 4. Attach a hoist to steering arm.

5. Remove shaft and the steering arm.
5-2.1 Removal
5-3.3 Steering Arm Installation
key switch. 1. Position steering arm in bracket and secure with
2. Open covers. shaft and screw.
3. Remove three screws and middle cover. 2. Install the return spring as described in paragraph
5-2.1.
4. Remove three screws and upper cover.
3. Reconnect harness to main harness.
5. Remove two screws and two washers.
Disengage the emergency stop switch and turn on key
5-2.2 Installation switch.
1. Install upper cover and secure with three
screws.
2. Install middle cover and secure with three
screws.
3. Close covers.
4. Install two screws and two washers.
5. Disengage the emergency stop switch and
turn on key switch.
5-4 BL-PDSR 30-0319 - 03-07-2019

SECTION 6
BRAKE SERVICING
6-1. BRAKES 6-1.3. TBrake Assembly Replacement

The brake system consists of a drive motor mounted 1. Block load wheels.
brake. This brake is spring applied and electrically 2. Remove the compartment covers as described in
released. paragraph 5-2.
6-1.1. Measurement 3. Disconnect electric brake from harness.
4. Remove the three mounting screws (Figure 6-1)
The "air gap" is the distance between the magnet
and the brake.
body and the rotor plate with the brake applied.
As the brake pads and rotor wear normally, the air 5. Place the new brake into position and secure
gap will increase and should be replaced when it with the three mounting screws.
measures more than 0.25mm. 6. Finally tighten the three mounting screws to 52
inlb (6 Nm).
.
7. Reconnect electric brake from harness.
8. Remove load wheel blocks and check operation.
9. Install the compartment covers as described in
paragraph5-2..
R8158
Figure 6-1 Brake Assembly
6-1.2. Stopping Distance Adjustment

The stopping distance of the truck should not require
adjustment. However, this distance should be
checked with each planned maintenance.
Using an unloaded truck, run 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.
BL-PDSR 30-0319 - 03-07-2019 6-1

NOTES
6-2 BL-PDSR 30-0319 - 03-07-2019

SECTION 7
DRIVING SYSTEM
7-1. DRIVE WHEEL 4. Remove three screws and encoder from the
steering motor.
key switch. 5. Disconnect harness from steering motor.
2. Remove the compartment covers as described in 6. Remove screw, lock washer, washer and gear
paragraph 5-2. from steering motor.
3. Loosen but do not remove the five bolts. 7. Remove four screws and lift steering motor
from the frame.
4. Jack up the truck so the drive wheel is off the
ground; then securely block the truck to prevent 8. Install new steering motor by reversing the steps
movement. above.
5. Remove five bolts, five washers, and drive
wheel from transmission. 7-4. Load Wheel
6. Install new drive wheel in reverse order of 7-4.1. Removal
removal.
1. Raise forks.
paragraph 5-2. 2. Engage the emergency stop switch and turn off
key switch.
8. Disengage the emergency stop switch and turn on
3. Block the drive wheel to prevent the truck from
key switch.
rolling.
7-2. TRANSMISSION 4. Jack up the forks to raise the load wheels off the
floor. Securely block the forks in the raised posi-
tion by positioning supports under both fork tips.
key switch.
5. Remove screw and retaining ring securing shaft.
2. Remove the compartment covers as described in
paragraph 5-2. NOTE: When shaft is removed, load wheel will drop
3. Remove the brake as described in paragraph 6- free.
1.1.
6. Remove shaft, load wheel and washers.
4. Disconnect harness from drive motor.
7. Remove bearings from load wheel.
5. Remove four screws, four lock washers, flat
washers, and motor from transmission. NOTE: Inspect the load wheel assembly. If the load
wheel is worn within 1/8" of the metal sleeve,
6. Disconnect position switch from harness.
or is cracked or damaged, replace the entire
7. Remove position switch from the frame. load wheel and bearing assembly.We recom-
8. Support the transmission and remove the six mend that both load wheel assemblies be
screws, six lock washers and six flat washers. replaced at the same time. This ensures level
and safe operation of the lift truck.
9. Slowly lower the transmission out the bottom of
the frame. 7-4.2. Repair
10. Install new transmission by reversing the steps
1. Remove bearings from wheels.
above.
2. Inspect bearings and replace if necessary.
7-3. STEERING MOTOR 3. Reassemble bearings in wheels.
1. Engage the emergency stop switch and turn off 4. Jack up the truck to raise the load wheels off the
key switch. floor. Securely block the forks in the raised posi-
2. Remove the compartment covers as described in tion by positioning supports under both fork tips.
paragraph 5-2.
3. Disconnect encoder from harness.
BL-PDSR 30-0319 - 03-07-2019 7-1

7-4.3. Load Wheel Installation
NOTE: Adjustable straddle shown, fixed straddle
similar.
1. Install 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.
key switch.
R8128
Figure 7-2 Load Wheel
DR_0004
Figure 7-1Transmission, Motor, Brake Mounting
7-2 BL-PDSR 30-0319 - 03-07-2019

SECTION 8
ELEVATION SYSTEM SERVICING
8-1. GENERAL
The elevation system includes the outer mast, inner
mast, lift linkage, lift chains, lift cylinder and ram head.
8-2. LIFT CHAIN LENGTH ADJUSTMENT

NOTE: The Telescopic trucks have two lift chains that
are adjusted at the cross member of the outer
mast. TRIMAST trucks have four lift chains.
The free lift chains are adjusted at the free
lift cylinder close to the cross member of the
inner mast. The secondary lift chains are
adjusted at the top of the outer mast.
1. Fully lower the lift carriage.

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 pins is parallel to the
masts.
CAUTION: At least 3 full threads must be pres-

ent below lower nut after adjustment.
7. Tighten jam nuts securely while maintaining

alignment of clevis pins.
DR_0027
key switch. Figure 8-1 Chain Assembly
9. Test chain by operating carriage. If slack is still
apparent, repeat above procedure.
BL-PDSR 30-0319 - 03-07-2019 8-1

8-3. LIFT CHAIN WEAR INSPECTION WARNING: Before attempting any adjustment, make
Both lift chains should be replaced when either chain
is worn enough to increase it’s length by 3% or more.
To make this determination proceed as follows. 3. Engage the emergency stop switch and turn off
Using a section of chain that sees the most frequent key switch.
operation over the chain sheaves, isolate a vertical 4. Remove cotter pin and clevis pin connecting
portion under tension from the weight of carriage and chain to chain anchor at the lift carriage.
forks. 5. Remove cotter pin and clevis pin connecting
Measure the distance between pin centers on 20 chain to chain anchor at the outer mast.
vertical links. If the section measures 12.88” or more, 6. Remove chain from sheave.
the chain should be replaced. 7. Position new chain on sheave.
New chain anchor, clevis pins and cotter pins should 8. Secure new chain to new chain anchor at the
be installed when chains are replaced. Never replace a outer mast with new clevis pin and new cotter
partial section of chain and never repair chain. Refer pin.
to paragraph 8-4. when installing new chain.
9. Connect the opposite end of new chain to new
chain anchor at the lift carriage with new clevis
8-4. LIFT CHAIN REPLACEMENT pin and new cotter pin.
8-4.1. Telescopic 10. Adjust the chains according to paragraph 8-2.
1. With the lift truck wheels securely blocked, raise 11. Disengage the emergency stop switch (and turn
the forks approximately three feet from floor and on key switch.
position blocks or strong supports under inner
mast.
2. Lower inner mast onto the support. Check that
arrangement is secure before proceeding.
8-2 BL-PDSR 30-0319 - 03-07-2019

DR_0029
Figure 8-2 Telescopic Mast Assembly
BL-PDSR 30-0319 - 03-07-2019 8-3

8-4.2. TRIMAST Free Lift Chain
1. With the lift truck wheels securely blocked, raise 8-4.3. TRIMAST Secondary Lift Chain
the forks approximately three feet from floor and
position blocks or strong supports under the lift 1. With the lift truck wheels securely blocked, raise
carriage. the forks approximately three feet from floor and
position blocks or strong supports under masts.
arrangement is secure before proceeding. 2. Lower inner mast onto the support. Check that
key switch. 3. Engage the emergency stop switch (and turn off
key switch.
WARNING: Before attempting any adjustment, make
certain power is disconnected. WARNING: Before attempting any adjustment, make
4. Remove cotter pin and clevis pin connecting

chain to chain anchor at the lift carriage. 4. Remove cotter pin and clevis pin connecting
chain to chain anchor at the inner mast.
5. Remove cotter pin and clevis pin connecting
chain to chain anchor at free lift cylinder. 5. Remove cotter pin and clevis pin connecting
chain to chain anchor at the outer mast.
6. Remove chain from sheave.
6. Remove chain from sheave.
7. Position new chain on sheave.
7. Position new chain on sheave.
8. Secure new chain to new chain anchor at the
outer mast with new clevis pin and new cotter 8. Secure new chain to new chain anchor at the
pin. outer mast with new clevis pin and new cotter
pin.
9. Connect the opposite end of new chain to new
chain anchor at the lift carriage with new clevis 9. Connect the opposite end of new chain to new
pin and new cotter pin. chain anchor at the inner mast with new clevis
pin and new cotter pin.
10. Adjust the chains according to paragraph 8-2.
key switch. 11. Disengage the emergency stop switch and turn on
key switch.
8-5. LIFT CYLINDERS

NOTE: Removal and repair of lift cylinders are
covered in SECTION 9.
8-4 BL-PDSR 30-0319 - 03-07-2019

DR_0014
Figure 8-3 Trimast Assembly
BL-PDSR 30-0319 - 03-07-2019 8-5

NOTES
8-6 BL-PDSR 30-0319 - 03-07-2019

SECTION 9
HYDRAULIC SYSTEM SERVICING
9-1. LINES AND FITTINGS 4. Telescopic Trucks: Refer to Figure 9-1 o r Fig-
ure 9-1.1 and remove leaking line or fitting and
WARNING: When forks are raised, pressure exists in replace it with a new line or fitting.
the hydraulic system lines and fittings. To
ensure release of pressure, forks must TRIMAST Trucks: Refer to Figure 9-2 or Figure
be fully lowered and the batteries discon- 9-2 .1 and remove leaking line or fitting and
nected before performing any mainte- replace it with a new line or fitting.
nance on the hydraulic system.
5. Check level of hydraulic oil. With lift carriage fully
NOTE: Leaking hydraulic fittings may be reme- lowered, fill reservoir with hydraulic oil to 1 inch
died by simply tightening fittings. If this below opening. Use hydraulic oil listed in Table
does not remedy the leak, the fittings 3-2.
or line must be replaced. 6. Disengage the emergency stop switch and turn on
key switch.
1. Lower forks fully.
7. Operate the lift and lower buttons to refill the
cylinder and lines with hydraulic oil.
key switch.
8. Check level of hydraulic oil. Hydraulic oil must be
3. Remove the compartment covers as described
1 inch below opening. If required, add hydraulic oil
in paragraph 5-2..
to bring to proper level. Use hydraulic oil listed in
CAUTION: Hydraulic oil can damage parts. Wipe off Table 3-2.
any oil immediately. Provide a container 9. Install the compartment covers as described in
under the line or fitting before discon- paragraph 5-2.
necting.
BL-PDSR 30-0319 - 03-07-2019 9-1

DR_0032
Figure 9-1 Hydraulic Lines for Telescopic Lift Cylinder
9-2 BL-PDSR 30-0319 - 03-07-2019

DR_0033
Figure 9-1.1 Hydraulic Lines for Telescopic Mast
BL-PDSR 30-0319 - 03-07-2019 9-3

DR_0021
Figure 9-2 Hydraulic Lines for Trimast Lift Cylinder
9-4 BL-PDSR 30-0319 - 03-07-2019

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

9-2. HYDRAULIC PUMP, MOTOR AND RESERVOIR 7. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use
The hydraulic pump/motor assembly can be disas-
hydraulic oil listed in Table 3-2.
sembled and repaired. However, a defective pump,
valve or motor requires replacement of that compo- 8. Install the compartment covers as described in
nent. paragraph 5-2
WARNING: When forks are raised, pressure exists in

the hydraulic system lines and fittings. To
ensure release of pressure, forks must
be fully lowered and the batteries discon-
nected before performing any mainte-
nance on the hydraulic system.
9-2.1. Removal
1. Lower forks fully.
key switch.
3. Remove the compartment covers as described in
paragraph 5-2..
NOTE: The reservoir and hose will be filled with

hydraulic oil. Place a container under the
pump assembly to catch any hydraulic oil.
4. Tag and disconnect electrical leads from motor

and solenoid. Refer to Figure 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 assembly, DR_0008
secure with four screws and four lock washers.

Figure 9-3 Hydraulic System
2. Reonnect hoses to pump/motor assembly.
3. Connect electrical leads to motor and solenoid.
Refer to Figure 10-3 and Figure 10-4...
4. Fill the hydraulic reservoir. Use hydraulic oil listed
in Table 3-2.
5. Disengage the emergency stop switch and turn
on key switch.
9-6 BL-PDSR 30-0319 - 03-07-2019

9-2.4. Lift Cylinder (Telescopic) 5. Remove guide ring, seal and snap ring from pis-
ton rod.
9-2.4.1. Removal
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
key switch.
WARNING: Before attempting any replacement,

make certain power is disconnected.
4. Remove screw, lock washer and flat washer.

5. Remove screw, lock washer and flat washer.
CAUTION: Hydraulic oil can damage parts. Wipe off

any oil immediately. Provide a container
under the line or fitting before discon-
necting.
6. Loosen hose at the bottom of lift cylinder and

manually push the ram down as far as possible.
The chains will become slack and need not be
removed.
7. Disconnect the hose from the bottom of lift cylin-
der.
8. Lift chains clear of sheaves and lay them aside.
WARNING: Support lift cylinder before performing DR_0031

the following steps to prevent cylinder
from falling. Figure 9-4 Lift Cylinder (Telescopic)
9. Tilt lift cylinder forward from their position in the lift 6. Coat all parts with hydraulic oil (Table 3-2).
truck.
7. Install guide ring and new seal and snap ring on
10. Raise lift cylinder assembly up and out of truck. piston rod.
9-2.4.2. Repair 8. Insert rod in cylinder tube.
9. Install wiper ring on gland nut.
CAUTION: To prevent damage, use proper pipe
clamp vise. The cylinder will be distorted 10. Install gland nut in cylinder tube.
if the vise is tightened too much.
9-2.4.3. Installation
1. Secure the lift cylinder in a vise, clamping lightly 1. Position the cylinder on outer mast.
at the base of the cylinder.
2. Tilt the cylinder back into position.
2. Remove gland nut.
3. Lift up the lift chains and position them on
3. Remove wiper ring from gland nut. sheaves.
4. Pull out piston rod. 4. Using a suitable lifting device, support the inner
mast and remove the supports.
BL-PDSR 30-0319 - 03-07-2019 9-7

5. Slowly lower the inner mast while lining up the lift
cylinder with its mounting taps.
6. Secure the top of the cylinder with screw, lock
washer (9) and flat washer.
Secure the bottom of the cylinder with screw,
7. lock washer and flat washer.
8. Reconnect the hose to the bottom of lift cylinder.
9. Adjust the chains according to paragraph 8-2..
in Table 3-2.
key switch.
13. Check level of hydraulic oil. If required, add
hydraulic oil to bring to proper level. Use hydraulic
oil listed in Table 3-2.
paragraph 5-2..
9-2.5. Lift Cylinder (TRIMAST Free Lift)

9-2.5.1. Removal
2. Engage the emergency stop switch and turn off DR_0020
key switch.
Figure 9-5 Trimast Free Lift Cylinder
make certain power is disconnected. 9-2.5.2. Repair
clamp vise. The cylinder will be distorted
if the vise is tightened too much
3. Using another lift truck or suitable jack, raise lift
carriage far enough to remove pressure on the 1. Secure the lift cylinder in a vise, clamping lightly
free lift cylinder at the base of the cylinder.
4. Remove cotter pin and clevis pin connecting 2. Remove gland nut.
chain to chain anchor at free lift cylinder.
3. Remove wiper and O-ring from gland nut.
5. Remove chains from sheaves.
4. Pull out piston rod.
6. Remove screw lock washer, flat washer, bracket
5. Remove guide ring, seal and snap ring from pis-
and ram head from cylinder.
ton rod.
CAUTION: Hydraulic oil can damage parts. Wipe off 6. Coat all parts with hydraulic oil (Table 3-2).
7. Install guide ring and new seal and snap ring on
piston rod.
necting.
8. Insert rod in cylinder tube.
7. Support cylinder and remove two screws two lock
9. Install wiper and O-ring on gland nut.
washers and two flat washers.
10. Install gland nut in cylinder tube.
8. Raise lift cylinder assembly up and out of truck.
9-8 BL-PDSR 30-0319 - 03-07-2019

1. Position cylinder on inner mast and secure with
two screws, two lock washers and two flat wash-
ers.
2. Reconnect the tube to the bottom of the cylinder.
3. Position ram head on cylinder and secure with
bracket, screw, lock washer, and flat washer.
4. Lift up the lift chains and position them on
sheaves.
key switch.
paragraph 5-2..
9-2.6. Lift Cylinder (TRIMAST Secondary)
9-2.6.1. Removal
key switch.
DR_0017

Figure 9-6 Trimast Lift Cylinder - Lift Height 157”
9-2.6.2. Repair
3. Remove screw, lock washer and flat washer clamp vise. The cylinder will be distorted
securing the top of cylinder to mast. if the vise is tightened too much.
4. Using another lift truck or suitable jack, raise mid- 1. Secure the lift cylinder in a vise, clamping lightly
dle mast far enough to remove pressure on the at the base of the cylinder.
secondary lift cylinder.
2. Remove gland nut.
CAUTION: Hydraulic oil can damage parts. Wipe off 3. Remove wiper and O-ring from gland nut.
4. Pull out piston rod.
necting. 5. Remove guide ring and seal from piston rod.
6. Coat all parts with hydraulic oil (Table 3-2).
5. Support cylinder and remove two bolts, two lock
washers, two flat washers, support and clamp. 7. Install guide ring and seal on piston rod.
6. Raise lift cylinder assembly up and out of truck. 8. Insert rod in cylinder tube.
9. Install O-ring and wiper on gland nut.
BL-PDSR 30-0319 - 03-07-2019 9-9

1. Using another lift truck or suitable jack, raise mid-
dle mast far enough to allow installation of the
secondary lift cylinder.
2. Slowly lower mast while aligning cylinder with the
top on mast.
3. Secure the top of cylinder with flat washer, lock
washer and screw.
4. Install clamp, support, two flat washers, two lock
washers and two bolts.
5. Reconnect the tube to the bottom of the lift cylin-
der.
in Table 3-2.
7. Disengage the emergency stop switch (and turn on
key switch.
8. Operate the lift and lower buttons to refill the cyl-
inder and lines with hydraulic oil.
paragraph 5-2.. DR_0018
9-2.7. Reach Cylinder

9-2.7.1. Removal
Figure 9-7 Reach Cylinder
key switch. 9-2.7.2. Repair
WARNING: Before attempting any replacement, CAUTION: To prevent damage, use proper pipe
make certain power is disconnected. clamp vise. The cylinder will be distorted
CAUTION: Hydraulic oil can damage parts. Wipe off 1. Secure the cylinder in a vise, clamping lightly at
any oil immediately. Provide a container the base of the cylinder.
under the line or fitting before discon- 2. Remove connector, lock washer and round nut
necting. from piston rod.
3. Disconnect the hose from the reach cylinder. 3. Remove gland nut.
4. Remove wiper ring, O-ring, seal and O-ring from
WARNING: Support reach cylinder before perform-
gland nut.
ing the following steps to prevent cylinder
from falling. 5. Pull out piston rod.
6. Remove guide ring and seal from piston rod.
4. Remove screw, shaft from the scissors base.
5. Remove screw, shaft from the scissors.
8. Install guide ring and new seal on piston rod.
6. Remove cylinder and out of truck.
9. Insert rod in cylinder tube.
10. Install wiper ring, O-ring, seal and O-ring on
gland nut.
12. Install connector, lock washer and round nut from
piston rod.
9-10 BL-PDSR 30-0319 - 03-07-2019

DR_0023
Figure 9-8 Hydraulic Lines for Reach Assembly
BL-PDSR 30-0319 - 03-07-2019 9-11

DR_0030
Figure 9-9 Telescopic Reach Assembly
9-12 BL-PDSR 30-0319 - 03-07-2019

DR_0015
Figure 9-10.1 Trimast Reach Assembly
BL-PDSR 30-0319 - 03-07-2019 9-13

1. Position the cylinder on scissors base and secure
with screw and shaft.
2. Position the cylinder on scissors and secure with
screw and shaft.
3. Reconnect the tube to the cylinder.
4. Operate the leading button to refill the cylinder
and lines with hydraulic oil.
paragraph 5-2.
9-2.8. Tilt Cylinder

9-2.8.1. Removal
key switch.

DR_0019
WARNING: Support shifter side assembly before Figure 9-11 Tilt Cylinder
performing the following steps .
9-2.8.2. Repair
3. Remove screw, shaft from the scissors assem-
clamp vise. The cylinder will be distorted
bly.
CAUTION: Hydraulic oil can damage parts. Wipe off
1. Secure the cylinder in a vise, clamping lightly at
the base of the cylinder.
necting. 2. Remove gland nut.
3. Remove wiper ring, O-ring, seal and O-ring
4. Disconnect the hose from the reach cylinder.
from gland nut.
WARNING: Support tilting cylinder before performing 4. Pull out piston rod.
the following steps to prevent cylinder
5. Remove guide ring and seals from piston rod.
from falling.
7. Install guide ring and new seals on piston rod.
5. Remove two screws, lock washer and flat washer 8. Insert rod in cylinder tube.
from the fork weldment.
9. Install wiper ring, O-ring, seal and O-ring on
6. Remove cylinder and out of truck gland nut.
9-14 BL-PDSR 30-0319 - 03-07-2019

DR_0028
Figure 9-12 Telescopic System
BL-PDSR 30-0319 - 03-07-2019 9-15

DR_0013
Figure 9-13 Trimast System
9-16 BL-PDSR 30-0319 - 03-07-2019

9-2.8.3. Installation 4. Position the shifter side assembly with two
screws and shafts and remove the supports.
1. Position the cylinder on the fork weldment and
secure with two screws, lock washer and flat 5. Operate the tilting button to refill the cylinder
washer. and lines with hydraulic oil.
2. Reconnect the tube to the cylinder. 6. Check level of hydraulic oil. If required, add
3. Using a suitable lifting device, support the shifter
side assembly.
paragraph 5-2..
BL-PDSR 30-0319 - 03-07-2019 9-17

NOTES
9-18 BL-PDSR 30-0319 - 03-07-2019

SECTION 10
ELECTRICAL COMPONENTS
10-1. ELECTRICAL CONTROL PANEL 3. Tag and disconnect all electrical cables which
connect to the control panel.
10-1.1. Maintenance
4. Remove four screws, four lock washers, four
NOTE: Erratic operation of the truck may be caused flat washers and control panel.
by defective controller components. Before
10-1.4. Panel Disassembly
removing the electrical panel, perform
troubleshooting procedures per Section 4- Refer to Figure 10-2 for location and identity of the
2.4, to determine corrective action to be major replacement components mounted on the
taken. panel and remove defective parts.
There are no user-serviceable parts inside the control- NOTE: Contactor (2or17) is not repairable and must
ler. No attempt should be made to open the control- be replaced if defective.
ler. Opening the controller may damage it and will void
the warranty. 10-1.5. Panel Installation
The controller is programmed at the factory specifi- 1. Install the control panel and secure with four
cally for the truck model on which it is equipped. It is screws, four lock washers and four flat washers.
important to replace the controller with the correct 2. Connect all electrical cables to the control panel
preprogrammed unit to assure proper performance as noted during removal.
settings intended for that particular truck. See Figure
4-1 for the preprogrammed controller number.
paragraph 5-2..
It is recommended that the controller exterior be
cleaned periodically, and if a hand held programmer is
key switch.
available, this periodic cleaning provides a good
opportunity to check the controller ’s diagnostic
10-2. HORN REPLACEMENT
history file. It is also recommended that the con-
troller ’s fault detection circuitry be checked 1. Engage the emergency stop switch and turn off
whenever the vehicle is serviced. key switch.
10-1.2. Cleaning in paragraph 5-2..
1. Engage the emergency stop switch and turn off 3. Tag and disconnect all electrical connections from
key switch. horn.
2. Remove the compartment covers as described 4. Remove screw, lock washer, flat washer and
in paragraph 5-2.. horn.
3. Remove any dirt or corrosion from the bus bar 5. Install new horn and secure with screw, lock
area. The controller should be wiped clean with a washer, flat washer.
moist rag. Allow it to dry before reconnecting the
battery. 6. Install the compartment covers as described in
paragraph 5-2..
4. Make sure the connections to the buss bars are
tight.Use two well insulated wrenches for this task 7. Disengage the emergency stop switch and turn on
in order to avoid steering the buss bars. key switch.
10-1.3. Panel Removal

1. Engage the emergency stop switchand turn off
key switch.
in paragraph 5-2..
BL-PDSR 30-0319 - 03-07-2019 10-1

DR_0009
10-2 BL-PDSR 30-0319 - 03-07-2019

Figure 10-1 Electrical System
DR_0010
BL-PDSR 30-0319 - 03-07-2019 10-3

Figure 10-2 Control Panel Assembly
DR_0011
10-4 BL-PDSR 30-0319 - 03-07-2019

Figure 10-3 Wiring Harness
DR_0012
10-3. PUMP MOTOR 10-5. DEADMAN SWITCH

The pump motor is replaceable but not repairable. 1. Disconnect harness from the deadman switch.
Refer to paragraph 9-2.. 2. Remove the two screws, and switches from
bracket.
10-4. DRIVE MOTOR 3. Position the new switches on bracket and
The drive motor exposed surfaces should be cleaned secure with the two screws.
at least once a month to assure proper cooling of 4. Reconnect harness to the deadman switch.
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..
BL-PDSR 30-0319 - 03-07-2019 10-5

NOTES
10-6 BL-PDSR 30-0319 - 03-07-2019

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.
BL-PDSR 30-0319 - 03-07-2019 11-1

NOTES
11-2 BL-PDSR 30-0319 - 03-07-2019

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

DR_0001
Figure 12-1 Frame
12-2 BL-PDSR 30-0319 - 03-07-2019

FRAME
Qty.
Pos. Part Number Description Notes
Reqd.
Used with 34” Straddle ID
1 2415-101000-00 FRAME 1 - Up to serial number
324200105
1a 2415-101000-0B FRAME 1 - Up from serial number
324200106
1ab 2415-101000-A0 FRAME 1 - Up to serial number
324200105
1c 2415-101000-AB FRAME 1 - Up from serial number
324200106
Used on trucks with Lift
1d 2415-101000-B0 FRAME 1 Height 189” and 42”
Straddle ID
2 2415-100001-1A COUNTER WEIGHT 1
3 2415-100003-10 HYDRAULIC PIPE BRACKET 1
4 0000-000432-00 SCREW 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 0000-000056-00 LOCKWASHER Ø6 2
18 0000-000123-00 FLATWASHER Ø6 2
19 2415-100002-00 STABILIZER BLOCK-L 1
20 2415-100001-00 STABILIZER BLOCK-R 1
Used up to serial number
21 0000-000516-00 SCREW M12×40 4
327160893
Used from serial number
21a 3020-010001-20 SCREW M12×50 4
327160894
22 0000-000373-00 FLATWASHER Ø12 4
23 2112-112002-00 MOUNTING BLOCK 2
24 2112-112006-00 WASHER A.R. As Required
BL-PDSR 30-0319 - 03-07-2019 12-3

DR_0002
Figure 12-2 Cover Assembly
12-4 BL-PDSR 30-0319 - 03-07-2019

COVER ASSEMBLY
Qty.
Reqd.
1 0000-000433-00 SCREW M8×12 4
2 2130-190002-00 MIDDLE COVER 1
3 0000-000649-00 SCREW M8×20 3
4 2130-190001-00 UPPER COVER 1
5 2130-172000-00 LEFT HINGE 1
6 2130-182000-00 RIGHT HINGE 1
7 2415-100100-1A COVER L 1
8 2415-100200-1A COVER R 1
326110025
8a 2415-100200-1B COVER R 1
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 LOCKWASHER Ø4 4
20 0000-000702-00 FLATWASHER Ø4 4
21 1146-151002-30 MANUAL HOLDER 1
22 0000-000119-00 SCREW M5x12 4
326110026
23 0000-000546-00 NUT M5 4
BL-PDSR 30-0319 - 03-07-2019 12-5

DR_0003
Figure 12-3 Battery Compartment
12-6 BL-PDSR 30-0319 - 03-07-2019

BATTERY COMPARTMENT
Qty.
Reqd.
1 0000-000109-00 SCREW M8×16 6
2 0000-000159-00 LOCKWASHER Ø8 8
3 0000-000176-00 FLATWASHER Ø8 6
4 2130-400001-40 HOSE CLAMP 1
5 2112-400002-00 HOSE CLAMP 1
6 2125-102200-0A ROLLER 5
324200105
6a 2415-112000-00 ROLLER 5
324200106
6b 2415-112000-B0 ROLLER 5
Height 189”
7 2130-151000-00 BATTERY ROLLER TRAY 1 324200105 - Does NOT
include rollers
7a 2415-111000-00 BATTERY ROLLER TRAY 1 324200106 - Does NOT
include rollers
7b 2415-111000-B0 BATTERY ROLLER TRAY 1 Height 189” - Does NOT
include rollers
8 0000-000321-00 SCREW M8×20 2
9 0000-000194-00 FLATWASHER Ø8 2
10 2130-160001-10 BAFFLE-PLATE 2
11 2415-100003-00 PROTECTION PLATE 1
325150188
11a 2415-100001-B0 PROTECTION PLATE 1
Height 189”
BL-PDSR 30-0319 - 03-07-2019 12-7

DR_0004
Figure 12-4 Transmission, Motor & Brake Assembly - Used up to serial number 325130600
12-8 BL-PDSR 30-0319 - 03-07-2019

TRANSMISSION, MOTOR & BRAKE ASSEMBLY - USED UP TO S/N 325130600
Qty.
Reqd.
1 2415-210000-10 MOTOR 3.3 KW 1
2 1280-210000-00 BRAKE ASSEMBLY 1
3 0000-000516-00 SCREW M12×40 6
4 0000-000060-00 LOCKWASHER Ø12 6
5 0000-000373-00 FLATWASHER Ø12 6
6 1280-520009-10 SWITCH WIRE HARNESS 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 WHEEL 1
19 0000-000283-00 BOLT M10×35 6
20 0000-000063-00 LOCKWASHER Ø10 6
21 0000-001281-00 SCREW M8×75 4
22 0000-000176-00 FLATWASHER Ø8 4
BL-PDSR 30-0319 - 03-07-2019 12-9

DR_0040
Figure 12-5 Transmission, Motor & Brake Assembly - Used from serial number 325130601
12-10 BL-PDSR 30-0319 - 03-07-2019

TRANSMISSION, MOTOR & BRAKE ASSEMBLY - USED FROM S/N 325130601
Qty.
Reqd.
1 2415-210000-10 MOTOR 3.3 KW 1
2 1280-210000-00 BRAKE ASSEMBLY 1
3 0000-000516-00 SCREW M12×40 6
4 0000-000060-00 LOCKWASHER Ø12 6
5 0000-000373-00 FLATWASHER Ø12 6
6 1280-520009-10 SWITCH WIRE HARNESS 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
Used between serial number
17 2415-220000-1A GEAR CASE ASSEMBLY 1
325130601 and 326140301
17a ZK18-240000-A0-02 GEAR CASE ASSEMBLY 1
326140302
18 2415-230000-1A DRIVE WHEEL 1
19 0000-001131-10 NUT M12×1.5 6
20 0000-000025-00 LOCKWASHER Ø12 6
21 0000-001281-00 SCREW M8×75 4
22 0000-000176-00 FLATWASHER Ø8 4
23 1120-240014-3A STUDS 6
24 0000-001287-10 SCREW M6x70 3
25 2333-210004-00 BRAKE LINING 1
26 2415-210001-10 ENCODER 1
BL-PDSR 30-0319 - 03-07-2019 12-11

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

GEAR CASE ASSEMBLY - USED UP TO SERIAL NUMBER 326140301
Qty.
Reqd.
-- 2415-220000-10 GEAR CASE ASSEMBLY 1
325130600 - Incl. pos. # 1-35
-- 2415-220000-1A GEAR CASE ASSEMBLY 1 325130601 and 326140301-
Incl. pos. # 1-35
1 2415-220001-10 GEAR CASE 1
2 2415-220002-10 COVER 1
3 2415-220008-10 O-RING 1
4 0000-000056-00 LOCKWASHER Ø6 8
5 0000-000055-00 SCREW M6×16 8
6 2415-GB10-00 SPIRAL BEVEL GEAR 1 The kit includes 2 gears
7 1120-240007-30 WASHER 1
8 1120-240008-30 LOCKING PLATE 1
9 0000-000277-00 BOLT M8×25 3
10 0000-001054-00 BEARING 2
11 2415-220009-10 COVER 2
12 0000-000077-00 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
325130600
18a 2415-220003-1A DRIVE SHAFT 1
325130601 and 326140301
19 2415-220018-10 COVER PLATE 1
20 2415-220010-10 SEAT 1
21 0000-001285-10 BEARING 2
22 2415-220012-10 PLATE 1
23 0000-000255-00 BOLT M8×20 6
24 0000-001699-00 SNAP RING ø55 1
25 2415-220015-10 SEAL WASHER TC35×62×7 1
26 0000-000762-00 CIRCLIP Ø62 1
27 0000-000183-00 RETAINER RING Ø35 1
28 0000-001282-10 BEARING 2
29 2415-220011-10 SLEEVE 1
30 2415-220013-10 GEAR 1
31 0000-000321-00 SCREW M8×20 8
32 0000-001286-10 BEARING 1
33 0000-001283-10 BEARING 1
34 2415-220016-10 DUST RING 1
35 2415-220017-10 DUST COVER 1
BL-PDSR 30-0319 - 03-07-2019 12-13

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

GEAR CASE ASSEMBLY - USED FROM SERIAL NUMBER 326140302
Qty.
Reqd.
-- ZK18-240000-A0-02 GEAR CASE ASSEMBLY 1 Incl. pos. # 1-37
1 0000-000911-00 BOLT M8×20 6
2 ZK18-240011-00 PLATE 1
3 ZK18-240017-00 WASHER A.R. As Required
4 ZK18-240009-00 DUST COVER 1
5 0000-001285-10 BEARING 2
6 ZK18-240004-00 SEAT 1
7 ZK18-240012-00 PLATE 1
8 3060-030000-13 SEAL WASHER TC35*62*7 1
9 0000-001445-00 BEARING 2
10 ZK18-240010-00 SLEEVE 1
This kit inlcudes 2 gears
11 ZK18-GBA0-00 GEAR KIT (Z1/Z2=28/94) 1
(Pos.# 11)
12 ZK18-240006-00 COVER PLATE 1
13 0000-000762-00 ELASTIC COLLAR Ø62 1
14 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
This kit inlcudes 2 gears
26 ZK18-GB00-10 GEAR KIT (Z1/Z2=6/43) 1
(Pos.# 26)
27 ZK18-240007-00 OUTPUT SHAFT 1
28 3090-010000-26 BEARING 2
29 3050-020000-18 ELASTIC COLLAR Ø140 1
30 3050-010000-19 RETAINER RING Ø100 1
31 3060-030000-14 SEAL WASHER TC140*100*12 1
32 ZK12-240011-00 WASHER A.R. As Required
33 0000-000321-00 SCREW M8×20 8
34 0000-000159-00 LOCKWASHER Ø8 8
35 ZK18-240015-00 GEAR 1
36 ZK12-240017-00 PLUG M14*1.5 1
37 ZK12-240016-00 PLUG M14*1.5 1
BL-PDSR 30-0319 - 03-07-2019 12-15

DR_0006
Figure 12-8 Steering Arm
12-16 BL-PDSR 30-0319 - 03-07-2019

STEERING ARM
Qty.
Reqd.
1 2415-340000-2A CONTROL POD ASSEMBLY 1
2 2333-330000-10 CONTROL HANDLE 1
3 0000-000010-00 SCREW M5×6 1
4 0000-000490-00 HARNESS CLAMP 1
5 0000-000011-00 BEARING 2
6 2130-350000-00 GAS SPRING 1
7 0000-000322-00 SCREW M8×25 5
8 0000-000114-00 NUT M52×1.5 1
9 0000-000143-00 CHECK WASHER Ø52×1.5 1
10 0000-000030-00 SCREW M10×16 1
11 0000-000429-00 SCREW M5×8 1
12 1120-300003-00 SHAFT 1
13 1120-300006-00 SPACER 1
14 0000-000028-00 SCREW M4×10 2
15 0000-000122-00 LOCKWASHER Ø4 2
16 0000-000377-00 SCREW M2×20 2
17 2333-300001-10 TURNING BRACKET 1
18 2322-300002-00 SLEEVE 1
19 0000-000142-00 BEARING 2
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 M8×20 5
32 1221-300006-00 TURNTABLE 1
33 0000-000109-00 SCREW M8×16 2
34 1221-300003-00 ROCKER POTENTIOMETER 1
35 1221-300002-00 MOUNTING PLATE 1
36 1221-520007-0A POTENTIOMETER 1
37 0000-000702-00 FLATWASHER Ø4 2
38 0000-000121-00 SCREW M4×35 2
39 2130-520004-00 WIRE HARNESS BELLY SWITCH 1
40 2415-520002-20 WIRE HARNESS 1
41 1220-560001-00 INCHING SWITCH I 2
42 1221-300004-00 PLATE 1
43 2333-320000-10 CONTROL POD BRACKET 1
44 0000-000055-00 SCREW M6×16 2
45 0000-000056-00 LOCK WASHER Ø6 2
BL-PDSR 30-0319 - 03-07-2019 12-17

DR_0007
Figure 12-9 Control Head Assembly
12-18 BL-PDSR 30-0319 - 03-07-2019

CONTROL HEAD ASSEMBLY
Qty.
Reqd.
1 2333-340001-00 COVER 1
2 2333-340002-00 CAP 1
3 2333-340003-00 CONTROL KNOB R 1
4 2333-340004-00 CONTROL KNOB L 1
5 2333-340005-00 HORN BUTTON 1
6 2333-340006-00 BELLY BUTTON COVER 1
7 2333-340007-00 TILT SWITCH 1
8 2415-340003-00 FORWARD & REVERSE SWITCH 1
9 2333-520005-10 HORN WIRE HARNESS 1
10 2333-520004-10 REVERSING SWITCH WIRE 1
11 2333-520003-10 ACCELERATOR ASSEMBLY 1
12 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 SWITCH WIRE 1
24 2333-340020-00 COVER 2
25 2333-340018-00 BRACKET 1
26 2333-340019-00 SCREW M3×10 1
27 2333-340022-00 SEALING PLATE 1
28 2333-340023-00 BUTTON 1
29 2333-340024-00 SCREW M5×12 2
30 2333-340025-00 SCREW ST2.9×20 2
31 2333-340026-00 BUSHING 2
32 2333-340027-00 BUSHING 2
BL-PDSR 30-0319 - 03-07-2019 12-19

DR_0008
Figure 12-10 Hydraulic System
12-20 BL-PDSR 30-0319 - 03-07-2019

HYDRAULIC SYSTEM
Qty.
Reqd.
1 2415-450000-10 PUMP & MOTOR ASSEMBLY 1
2 0000-000620-00 BOLT M 6×16 4
3 0000-000056-00 LOCKWASHER Ø6 4
4 2125-420001-00 MAGNET 1
5 0000-000109-00 SCREW M8×16 5
6 0000-000159-00 LOCKWASHER Ø8 5
7 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
327150483
18a 2415-412000-10 FILTER 1
327150484
BL-PDSR 30-0319 - 03-07-2019 12-21

DR_0045
Figure 12-11 Triple Solenoid Valve
12-22 BL-PDSR 30-0319 - 03-07-2019

TRIPLE SOLENOID VALVE
Qty.
Reqd.
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
BL-PDSR 30-0319 - 03-07-2019 12-23

DR_0037
Figure 12-12 Pump and Motor Assembly
12-24 BL-PDSR 30-0319 - 03-07-2019

PUMP AND MOTOR ASSEMBLY
Qty.
Reqd.
1 2415-450001-10 MOTOR 1
2 2415-450002-10 COUPLING 1
3 2415-450003-10 ADAPTER 1
4 2415-450004-10 CHECK VALVE 1
5 2415-450005-10 PLUG 2
6 2415-450006-10 FLANGE 1
7 2415-450007-10 PUMP 1
8 2415-450008-10 OIL SUCTION PIPE 3
9 2415-450009-10 FILTER 1
10 2415-450010-10 RETURN OIL PIPE 1
11 2415-450011-10 PLUG 1
12 2415-450012-10 SOLENOID VALVE 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, 24×2.4 1
24 2415-450022-10 O-RING, 12.5×1.8 1
25 2415-450023-10 O-RING, 11.2×1.8 1
26 2415-450024-10 O-RING, 9.5×1.8 1
The kit includes:
Pos. 21 (2 PCS),
Pos. 22 (10 PCS),
27 2415‐451000‐10 SEAL KIT 1 Pos. 23 (1 PCS),
Pos. 24 (6 PCS),
Pos. 25 (5 PCS),
Pos. 26 (5 PCS).
BL-PDSR 30-0319 - 03-07-2019 12-25

DR_0009
Figure 12-13 Electrical System
12-26 BL-PDSR 30-0319 - 03-07-2019

ELECTRICAL SYSTEM
Qty.
Reqd.
With Hour meter dial set
1 1115‐510006‐2B‐01 BDI WITH HOUR METER 1
to: M = Industrial Battery,
With Hour meter dial set
1a 1115‐510006‐2B‐02 BDI WITH HOUR METER 1
to: Q = Maint.Free Battery
2 1220-520007-0D BDI WRING HARNESS 3 PIN 1
See Control Panel
3 -- CONTROL PANEL ASSEMBLY 1
Assembly Section
4 0000-000498-00 SCREW M6×30 2
5 1120-500009-10 BATTERY CONNECTOR ASSEMBLY 1
6 0000-000433-00 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 M12×15 1
19 0000-000060-00 LOCKWASHER Ø12 1
20 0000-000373-00 FLATWASHER Ø12 1 Optional Equipment
21 2415-100002-B0 INSTALLATION PLATE 1 (used for Travel Alarm)
22 3712-405000-00 ALARM BUZZER 1 (Pos. 18-24)
23 0000‐000380‐00 FLATWASHER Ø6 1
24 0000-000055-00 SCREW M6×16 1
BL-PDSR 30-0319 - 03-07-2019 12-27

DR_0039
Figure 12-14 Proportional Valve Circuit Board
12-28 BL-PDSR 30-0319 - 03-07-2019

PROPORTIONAL VALVE CIRCUIT BOARD
Qty.
Reqd.
Used from Serial Number
1 0000-001024-00 SCREW M3X10 2
325150188
2 0000-001138-00 SCREW 2
325150188
3 0000-000924-00 NUT M3 2
325150188
Prior to Serial Number
325150188 - it was
4 2415-520004-20 CIRCUIT BOARD 1
mounted without the box
by the Drive motor.
5 2415-100300-10 CIRCUIT BOARD BOX 1
325150188
BL-PDSR 30-0319 - 03-07-2019 12-29

DR_0010
Figure 12-15 Control Panel Assembly
12-30 BL-PDSR 30-0319 - 03-07-2019

CONTROL PANEL ASSEMBLY
Qty.
Reqd.
1 2415-510001-20 CONTROL PANEL 1
2 2110-500007-00-70 CONTROLLER 1
3 0000-000380-00 FLATWASHER Ø6 8
4 0000-000056-00 LOCKWASHER Ø6 8
5 0000-000015-00 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
18 2415-530008-20 STEERING CONTROLLER + 1
BL-PDSR 30-0319 - 03-07-2019 12-31

DR_0011
12-32 BL-PDSR 30-0319 - 03-07-2019

WIRING HARNESS
Qty.
Reqd.
1 2415-520001-2E MAIN WIRING HARNESS 1
2 1120-500010-00 FUSE 10A 2
3 2415-520009-20-01 MASTER WIRING HARNESS 1 325150405 - for Lift
Height 106”
3a 2415-520009-20-03 MASTER WIRING HARNESS 1 325150405 - for Lift
Height 126”
3b 2415-520009-20-08 MASTER WIRING HARNESS 1 325150405 - for Lift
Height 157”
3c 2415-520009-20-10 MASTER WIRING HARNESS 1 325150405 - for Lift
Height 189”
Used up to Serial Number
4 2415-520005-00-01 POWER CHAIN WIRING HARNESS 1 325150404 for Lift Height
102”
4a 2415-520005-0A-03 POWER CHAIN WIRING HARNESS 1 325150404 for Lift Height
106”
4b 2415-520005-00-02 POWER CHAIN WIRING HARNESS 1 325150404 for Lift Height
126”
4c 2415-520005-2A-07 POWER CHAIN WIRING HARNESS 1 325150404 for Lift Height
157”
4d 2415-520005-2A-09 POWER CHAIN WIRING HARNESS 1 325150404 for Lift Height
189”
4e 2415-520008-20 POWER CHAIN WIRING HARNESS 1
325150405
5 2415-520003-2A SOLENOID VALVE WIRING HARNESS 1
6 2415-520010-20 WIRING HARNESS 1
325150405
BL-PDSR 30-0319 - 03-07-2019 12-33

DR_0041
Figure 12-17 Travel Alarm Wiring Harness
12-34 BL-PDSR 30-0319 - 03-07-2019

TRAVEL ALARM WIRING HARNESS
Qty.
Reqd.
1 2415-521002-B0 TRAVEL ALRM WIRING HARNESS 1 Travel Alarm is Optional
BL-PDSR 30-0319 - 03-07-2019 12-35

DR_0012
Figure 12-18 Cable Assembly
12-36 BL-PDSR 30-0319 - 03-07-2019

CABLE ASSEMBLY
Qty.
Reqd.
1 2415-530003-2A MOTOR 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
BL-PDSR 30-0319 - 03-07-2019 12-37

DR_0013
Figure 12-19 Trimast System Assemblies
12-38 BL-PDSR 30-0319 - 03-07-2019

TRIMAST SYSTEM ASSEMBLIES
Qty.
Reqd.
See Trimast Assembly
1 -- TRIMAST LIFTING SYSTEM 1
Section
See Trimast Reach
2 -- TRIMAST REACH ASSEMBLY 1
Assembly Section
See Side Shift Assembly
3 -- SIDE SHIFTER ASSEMBLY 1
Section
4 2415-612000-10 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 MAIN ROLLER ASSEMBLY 4
15 2415-612005-10 DUST SNAP 4
16 0000-000183-00 RETAINER RING Ø35 4
BL-PDSR 30-0319 - 03-07-2019 12-39

DR_0014
Figure 12-20 Trimast Assembly
12-40 BL-PDSR 30-0319 - 03-07-2019

TRIMAST ASSEMBLY
Qty.
Reqd.
1 2415-611000-1F-02 OUTER MAST 1 Used for Lift Height 157”
1a 2415-611000-1F-05 OUTER MAST 1 Used for Lift Height 189”
Used for Lift Height 189” -
1b 2415-611000-B0 OUTER MAST 1
When Option Travel Alarm
2 2415-621000-1D-02 MIDDLE MAST 1 Used for Lift Height 157”
2a 2415-621000-1D-05 MIDDLE MAST 1 Used for Lift Height 189”
3 2415-631000-1D-02 INNER MAST 1 Used for Lift Height 157”
3a 2415-631000-1D-05 INNER MAST 1 Used for Lift Height 189”
4 2130-420000-30-01 FREE LIFT CYLINDER 1 Used for Lift Height 157”
4a 2130-420000-30-03 FREE LIFT CYLINDER 1 Used for Lift Height 189”
5 2415-600004-10 ROLLER BRACKET 1
6 2214-600001-00 CHAIN ROLLER 4
7 0000-000183-00 RETAINER RING Ø35 12
8 2415-600500-10 MIDDLE CYLINDER BRACKET 1
9 0000-000593-00 BOLT M12×40 1
10 0000-000060-00 LOCKWASHER Ø12 6
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 0000-000122-00 LOCKWASHER Ø4 4
23 0000-000028-00 SCREW M4×10 4
25 2415-600017-1A SENSOR BRACKET 1
26 2415-520006-20 SPEED CUT OFF SWITCH WIRING 1
27 3120-600001-00 GUIDE PLATE 2
28 58A04-30T01 WASHER A.R. As Required
29 0000-001210-00 BOLT M16X55 2
327100496
29a 0000-001210-00 BOLT M16X55 4
327100497
30 0000-000190-00 FLATWASHER Ø16 2
31 2415-650000-10-05 LIFT CYLINDER 2 Used for Lift Height 157”
31a 2415-650000-10-07 LIFT CYLINDER 2 Used for Lift Height 189”
32 2415-600007-10 CYLINDER BRACKET 2
33 0000-000277-00 BOLT M8X25 4
34 0000-000159-00 LOCKWASHER Ø8 12
35 0000-000176-00 FLATWASHER Ø8 10
BL-PDSR 30-0319 - 03-07-2019 12-41

DR_0014
Figure 12-20 Trimast Assembly - Continued
12-42 BL-PDSR 30-0319 - 03-07-2019

TRIMAST ASSEMBLY - CONTINUED
Qty.
Reqd.
36 0000-001415-00 BOLT M10X30 2
37 0000-000063-00 LOCKWASHER Ø10 2
38 0000-000175-00 FLATWASHER Ø10 2
39 0000-001412-00 BOLT M8X40 2
40 2415-600019-00 BUSHING 1
41 2415-600008-10 DRAG CHAIN UPPER TIE PLATE 1
42 2415-600018-00 ROLLER 1
43 2415-600009-1A BUSHING 1
44 2415-600010-1A CHAIN ROLLER 1
45 2415-600012-1A BUSHING 1
46 2415-600011-1A DUAL PULLEY 1
47 0000-001414-00 BOLT M12×80 1
48 0000-000996-00 BOLT M16X45 2
49 2415-420100-10 WELDMENT 1
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 Lift Height 157”
59a 2415-520007-2B-10 LIFT LIMIT PROXIMITY SWITCH WIRING 1 Used for Lift Height 189”
60 2415-600022-00 BEARING 3
61 3316-500004-10 BEARING 2
62 2415-600020-00 BEARING 2
63 2415-612001-10 SCREW 8
64 2415-612002-10 SNAP RING 8
65 2415-612003-10 SHAFT ROLLER 8
66 2415-612004-10 MAIN ROLLER 8
67 2415-612005-10 DUST SNAP 8
BL-PDSR 30-0319 - 03-07-2019 12-43

DR_0042
Figure 12-21 Option for Trimast 189”
12-44 BL-PDSR 30-0319 - 03-07-2019

OPTION FOR TRIMAST 189”
Qty.
Reqd.
Option, for the travel
1 CK10-520015-10 WARNING LIGHT 1
alarm.
2 2415-521001-B0 WARNING LIGHT WIRING 1
alarm.
3 2333-500001-50 BRACKET 1
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
189” (4800mm), for the
10 2415-611000-B0 EXTERNAL MAST 1
travel alarm
BL-PDSR 30-0319 - 03-07-2019 12-45

DR_0015
Figure 12-22 Trimast Reach Assembly
12-46 BL-PDSR 30-0319 - 03-07-2019

TRIMAST REACH ASSEMBLY
Qty.
Reqd.
1 2415-641100-1B SCISSORS BASE 1
2 -- SCISSORS 1 See Scissor Section
3 2415-644000-1C FORK WELDMENT 1
4 2125-600005-00 BUFFER BLOCK 5
5 0000-000321-00 SCREW M8X20 5
6 2415-441000-30 TRIPLE SOLENOID VALVE 1
7 0000-000006-00 SCREW M6X30 3
8 0000-000056-00 LOCKWASHER Ø6 5
9 0000-000123-00 FLATWASHER Ø6 5
10 2415-640600-10 SHORT PIN WELDING 2
11 0000-000126-00 SCREW M6X16 4
12 2415-640006-10 BEARING 2
13 2415-640200-10 LONG PIN WELDING 2
14 2415-640001-10 BEARING 2
15 2415-640002-10 WASHER 6
16 0000-000700-00 SCREW M8X16 4
17 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
28 2415-640003-10 BEARING 2
29 2415-647000-10 REACH CYLINDER LEFT 1
30 2415-648000-10 REACH CYLINDER RIGHT 1
31 2415-420200-10 EIGHT-WAY VALVE 1
32 0000-000109-00 SCREW M8×16 2
33 0000-000159-00 LOCKWASHER Ø8 2
34 0000-000105-00 FLATWASHER Ø8 2
35 2415-646000-10 TILT CYLINDER 1
36 0000-000283-00 BOLT M10X35 2
37 0000-000063-00 LOCKWASHER Ø10 2
38 0000-000007-00 FLATWASHER Ø10 2
39 2415-640500-10 LONG PIN WELDING 2
BL-PDSR 30-0319 - 03-07-2019 12-47

DR_0015
Figure 12-22 Trimast Reach Assembly - Continued
12-48 BL-PDSR 30-0319 - 03-07-2019

TRIMAST REACH ASSEMBLY - CONTINUED
Qty.
Reqd.
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
BL-PDSR 30-0319 - 03-07-2019 12-49

DR_0016
Figure 12-23 Telescopic and Trimast Scissor Assembly
12-50 BL-PDSR 30-0319 - 03-07-2019

TELESCOPIC AND TRIMAST SCISSOR ASSEMBLY
Qty.
Reqd.
1 0000-000088-00 SCREW M4X8 8
2 0000-000122-00 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
BL-PDSR 30-0319 - 03-07-2019 12-51

DR_0017
Figure 12-24 Trimast Lift Cylinder
12-52 BL-PDSR 30-0319 - 03-07-2019

TRIMAST LIFT CYLINDER
Qty.
Reqd.
-- 2415-650000-10-05 LIFT CYLINDER 1 Used for lift height 157”
-- 2415-650000-10-07 LIFT CYLINDER 1 Used for lift height 189”
KIT 2415-2BG SEAL KIT FOR LIFTING CYLINDER 1 Includes pos. # 1, 2 & 9
1 0000-000084-00 RING WIPER 35×43×5-6.5 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 2415-681000-10-05 CYLINDER TUBE 1 Used for Lift Height 157”
11a 2415-681000-10-07 CYLINDER TUBE 1 Used for Lift Height 189”
BL-PDSR 30-0319 - 03-07-2019 12-53

DR_0018
Figure 12-25 Reach Cylinder
12-54 BL-PDSR 30-0319 - 03-07-2019

REACH CYLINDER
Qty.
Reqd.
-- 2415-647000-10 REACH CYLINDER LEFT 1
-- 2415-648000-10 REACH CYLINDER RIGHT 1
One Seal Kit per cylinder
KIT 2415-QYG SEAL KIT FOR REACH CYLINDER 1
Includes Pos. # 4,5,6,8 & 10
1 2415-640005-10 CONNECTOR 1
2 2415-647003-10 LOCK 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 REACH CYLINDER TUBE 1
13 2415-647008-10 STEEL-BACKED BEARING 20X35X12X16 1
14 2415-647009-10 INTERNAL CIRCLIP 35 1
BL-PDSR 30-0319 - 03-07-2019 12-55

DR_0019
Figure 12-26 Tilt Cylinder
12-56 BL-PDSR 30-0319 - 03-07-2019

TILT CYLINDER
Qty.
Reqd.
-- 2415-646000-10 TILT CYLINDER 1
KIT 2415-QXG SEAL 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
BL-PDSR 30-0319 - 03-07-2019 12-57

DR_0020
Figure 12-27 Trimast Free Lift Cylinder
12-58 BL-PDSR 30-0319 - 03-07-2019

TRIMAST FREE LIFT CYLINDER
Qty.
Reqd.
-- 2130-420000-30-01 FREE LIFT CYLINDER 1 Used for Lift Height 157”
-- 2130-420000-30-03 FREE LIFT CYLINDER 1 Used for Lift Height 189”
KIT 2130-3ZG SEAL KIT 1 Includes 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
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
BL-PDSR 30-0319 - 03-07-2019 12-59

DR_0021
Figure 12-28 Hydraulic Lines for Trimast Lift Cylinder
12-60 BL-PDSR 30-0319 - 03-07-2019

HYDRAULIC LINES FOR TRIMAST LIFT CYLINDER
Qty.
Reqd.
1 0000-000069-00 WASHER Ø16 4
2 2701-161600-00 CONNECTOR M16×1.5-M16×1.5 4
3 2415-420300-10 HYDRAULIC LINEASSEMBLY 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 HYDRAULIC LINEASSEMBLY RIGHT 1
BL-PDSR 30-0319 - 03-07-2019 12-61

DR_0022
Figure 12-29 Hydraulic Lines for Trimast
12-62 BL-PDSR 30-0319 - 03-07-2019

HYDRAULIC LINES FOR TRIMAST
Qty.
Reqd.
1 2415-427000-10-01 HYDRAULIC LINE ASSEMBLY 2
325200481 - for Lift Height 157”
1a 2415-427000-1B-01 HYDRAULIC LINE ASSEMBLY 2
1b 2415-427000-10-03 HYDRAULIC LINE ASSEMBLY 2
1bc 2415-427000-1B-03 HYDRAULIC LINE ASSEMBLY 2
2 2415-430500-1A-01 OIL PIPE 2 Used for Lift Height 157”
2a 2415-430500-1A-03 OIL PIPE 2 Used for Lift Height 189”
3 2415-428000-10-02 HYDRAULIC LINE ASSEMBLY 1
3a 2415-428000-1B-02 HYDRAULIC LINE ASSEMBLY 1
3b 2415-428000-10-04 HYDRAULIC LINE ASSEMBLY 1
3c 2415-428000-1B-04 HYDRAULIC LINE ASSEMBLY 1
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 0000-000123-00 FLATWASHER Ø6 1
10 2415-600003-1A BRACKET 1
11 0000-000028-00 SCREW M4×10 4
12 0000-000122-00 LOCKWASHER Ø4 4
13 0000-000089-00 FLATWASHER Ø4 4
14 2415-430600-1A-01 HYDRAULIC LINE 2 Used for Lift Height 157”
14a 2415-430600-1A-03 HYDRAULIC LINE 2 Used for Lift Height 189”
15 2415-429000-10 VALVE BLOCK 1
16 2415-600002-10 BRACKET 1
17 0000-000032-00 SCREW M6X20 2
18 2415-640009-10 MOUNTING PLATE 1
19 0000-000322-00 SCREW M8X25 2
20 2415-430300-10 HYDRAULIC LINE B 1
21 2415-430200-10 HYDRAULIC LINE A 1
22 2702-141400-00 CONNECTOR G1/4-M14×1.5 1
23 0000-000044-00 WASHER Ø14 2
BL-PDSR 30-0319 - 03-07-2019 12-63

DR_0023
Figure 12-30 Hydraulic Lines for Reach Assembly (Telescopic and Trimast)
12-64 BL-PDSR 30-0319 - 03-07-2019

HYDRAULIC LINES FOR REACH ASSEMBLY (TELESCOPIC AND TRIMAST)
Qty.
Reqd.
1 2415-431000-10 HYDRAULIC LINE FROM A1 TO LEFT CYLINDER 1
2 2415-433000-10 HYDRAULIC LINE FROM B1 TO LEFT CYLINDER 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 BOLT M14X35 2
13 2402-143500-00 BOLT G1/4×35 3
BL-PDSR 30-0319 - 03-07-2019 12-65

DR_0024
Figure 12-31 Side Shift Assembly
12-66 BL-PDSR 30-0319 - 03-07-2019

SIDE SHIFT ASSEMBLY
Qty.
Reqd.
1 0000-000221-00 BOLT M12×30 4
2 0000-000060-00 LOCKWASHER Ø12 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
BL-PDSR 30-0319 - 03-07-2019 12-67

DR_0038
Figure 12-32 Side Shift Breakdown
12-68 BL-PDSR 30-0319 - 03-07-2019

SIDE SHIFT BREAKDOWN
Qty.
Reqd.
1 2415-645160-30 BOLT M12×30 2
2 0000-000032-00 SCREW 8
3 0000-000082-00 WIPER SEAL 2
4 2415-645180-30 CYLINDER HEAD 1
5 2415-645111-00 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 0000-001180-00 SCREW M16×1.5×40 4
BL-PDSR 30-0319 - 03-07-2019 12-69

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

DRAG CHAIN ASSEMBLY I - TRIMAST FREE LIFT CYLINDER
Qty.
Reqd.
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
BL-PDSR 30-0319 - 03-07-2019 12-71

DR_0026
Figure 12-34 Drag Chain Assembly II - Trimast Lift Cylinder
12-72 BL-PDSR 30-0319 - 03-07-2019

DRAG CHAIN ASSEMBLY II - TRIMAST LIFT CYLINDER
Qty.
Reqd.
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
BL-PDSR 30-0319 - 03-07-2019 12-73

DR_0027
Figure 12-35 Chain Assembly
12-74 BL-PDSR 30-0319 - 03-07-2019

CHAIN ASSEMBLY
Qty.
Reqd.
1 2125-640001-00 BOLT 1
2 0000-000187-00 NUT M16×1.5 3
3 0000-000188-00 COTTER PIN Ø3.2×20 2
4 2125-640002-00 PIN 2
5 2415-600100-00-01 CHAIN ASSEMBLY 1 Used for Lift Height 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 2125-640003-00 CHAIN ANCHOR 1
7 0000-000686-00 COTTER PIN Ø3.2×32 1
BL-PDSR 30-0319 - 03-07-2019 12-75

DR_0028
Figure 12-36 Telescopic System Assemblies
12-76 BL-PDSR 30-0319 - 03-07-2019

TELESCOPIC SYSTEM ASSEMBLIES
Qty.
Reqd.
See Trimast Assembly
1 -- TELESCOPIC MAST LIFTING SYSTEM 1
Section
See Telescopic Reach
2 -- TELESCOPIC REACH ASSEMBLY 1
Assembly Section
See Side Shift Assembly
3 -- SIDE SHIFTER ASSEMBLY 1
Section
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 2415-612004-10 Main Roller Assembly 4
15 2415-612005-10 Dust Snap 4
16 0000-000183-00 Retainer Ring Ø35 4
BL-PDSR 30-0319 - 03-07-2019 12-77

DR_0029
Figure 12-37 Telescopic Mast Assembly
12-78 BL-PDSR 30-0319 - 03-07-2019

TELESCOPIC MAST ASSEMBLY
Qty.
Reqd.
1 2415-621000-00-01 INNER MAST 1
Used up to 01-27-2016
1a 2415-621000-0A-01 INNER MAST 1
Used from 01-28-2016
1b 2415-621000-0A-03 INNER MAST 1 Used for Lift Height 106”
Used for Lift Height 126”-
1c 2415-621000-00-02 INNER MAST 1
Used up to 01-27-2016
Used for Lift Height 126”-
1d 2415-621000-0A-02 INNER MAST 1
Used from 01-28-2016
2 2415-611000-00-01 OUTER MAST 1 Used for Lift Height 102”
2a 2415-611000-0A-03 OUTER MAST 1 Used for Lift Height 106”
2b 2415-611000-00-02 OUTER MAST 1 Used for Lift Height 126”
3 2415-650000-00-01 LIFT CYLINDER 2 Used for Lift Height 102”
3a 2415-650000-0A-03 LIFT CYLINDER 2 Used for Lift Height 106”
3b 2415-650000-00-02 LIFT CYLINDER 2 Used for Lift Height 126”
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 0000-000183-00 RETAINER RING Ø35 8
14 2415-600005-1A CHAIN ROLLER 1
15 2415-600002-00 BRACKET 1
16 0000-001413-00 BOLT M12X100 1
17 0000-000060-00 LOCKWASHER Ø12 1
18 0000-000222-00 FLATWASHER Ø12 1
19 0000-000165-00 NUT M12 1
20 2415-600006-1A BUSHING 1
21 2415-600022-00 BEARING 1
23 2415-600300-00 SPROCKET SEAT 1
24 0000-000255-00 SCREW M8X20 6
25 2125-600005-00 BUFFER BLOCK 2
26 2415-600008-10 DRAG CHAIN UPPER BRACKET 1
27 0000-001024-00 SCREW M3X10 2
28 0000-000995-00 LOCK WASHER Ø3 2
29 0000-000999-00 FLAT WASHER Ø3 2
BL-PDSR 30-0319 - 03-07-2019 12-79

DR_0029
Figure 12-37 Telescopic Mast Assembly - Continued
12-80 BL-PDSR 30-0319 - 03-07-2019

TELESCOPIC MAST ASSEMBLY - CONTINUED
Qty.
Reqd.
31 0000-000771-00 BOLT M16X40 2
32 0000-001412-00 BOLT M8X40 2
33 0000-000210-00 FLATWASHER Ø8 2
34 0000-001210-00 BOLT M16X55 2
327100496
34a 0000-001210-00 BOLT M16X55 4
327100497
35 0000-000190-00 FLATWASHER Ø16 2
36 2415-520006-20 SPEED LIMIT SWITCH WIRING 1
37 2415-600016-1A LIMIT SWITCH PLATE 1
38 0000-000118-00 SCREW M8X10 6
39 2415-600018-10 SENSOR BRACKET 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”
45 2415-600002-2A SENSOR BRACKET 1
46 3120-600001-00 GUIDE PLATE 4
47 58A04-30T01 WASHER A.R. As Required
48 0000-000952-00 PIN 2 Used from 01-28-2016
49 0000-000188-00 COTTER PIN Ø3.2×20 2 Used from 01-28-2016
50 2415-612001-10 SCREW 4
51 2415-612002-10 SNAP RING 4
52 2415-612003-10 SHAFT ROLLER 4
53 2415-612004-10 MAIN ROLLER 4
54 2415-612005-10 DUST SNAP 4
BL-PDSR 30-0319 - 03-07-2019 12-81

DR_0030
Figure 12-38 Telescopic Reach Assembly
12-82 BL-PDSR 30-0319 - 03-07-2019

TELESCOPIC REACH ASSEMBLY
Qty.
Reqd.
1 2415-641100-00 SCISSORS BASE 1
2 -- SCISSORS 1 See Scissor Section
3 2415-644000-1C FORK WELDMENT 1
4 2125-600005-00 BUFFER BLOCK 5
5 0000-000321-00 SCREW M8X20 5
6 2415-441000-30 TRIPLE SOLENOID VALVE 1
7 0000-000006-00 SCREW M6X30 3
8 0000-000056-00 LOCKWASHER Ø6 7
9 0000-000123-00 FLATWASHER Ø6 7
11 0000-000126-00 SCREW M6X16 4
12 2415-640006-10 BEARING 2
13 2415-640200-10 LONG PIN WELDING 2
14 2415-640001-10 BEARING 2
15 2415-640002-10 WASHER 6
16 0000-000700-00 SCREW M8X16 4
17 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
28 2415-640003-10 BEARING 2
29 2415-647000-10 REACH CYLINDER LEFT 1
30 2415-648000-10 REACH CYLINDER RIGHT 1
31 2415-420200-10 EIGHT-WAY VALVE 1
32 0000-000109-00 SCREW M8×16 2
33 0000-000159-00 LOCKWASHER Ø8 2
34 0000-000105-00 FLATWASHER Ø8 2
35 2415-646000-10 TILT CYLINDER 1
36 0000-000283-00 BOLT M10X35 2
37 0000-000063-00 LOCKWASHER Ø10 2
38 0000-000007-00 FLATWASHER Ø10 2
39 2415-640500-10 LONG PIN WELDING 2
40 2415-600014-10 COVER 1
BL-PDSR 30-0319 - 03-07-2019 12-83

DR_0030
Figure 12-38 Telescopic Reach Assembly - Continued
12-84 BL-PDSR 30-0319 - 03-07-2019

TELESCOPIC REACH ASSEMBLY - CONTINUED
Qty.
Reqd.
41 0000-000028-00 BOLT M4X10 3
42 0000-000122-00 LOCKWASHER 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
324200106
47 0000-000055-00 SCREW M6X16 2
324200106
48 3316-610001-10 FIXED BLOCK 2
324200106
49 0000-000988-00 BOLT M6X30 2
324200106
BL-PDSR 30-0319 - 03-07-2019 12-85

DR_0031
Figure 12-39 Telescopic Lift Cylinder
12-86 BL-PDSR 30-0319 - 03-07-2019

TELESCOPIC LIFT CYLINDER
Qty.
Reqd.
-- 2415-650000-00-01 LIFT CYLINDER 1 Used for Lift Height 102”
-- 2415-650000-0A-03 LIFT CYLINDER 1 Used for Lift Height 106”
-- 2415-650000-00-02 LIFT CYLINDER 1 Used for Lift Height 126”
KIT 2415-2BG-0A SEAL KIT 1 Includes Pos. # 2 & 10
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
5b 2415-651000-20-02 CYLINDER TUBE 1 Used for Lift Height 126”
6 2415-650002-10 PISTON 1
7 2125-410003-00 COLLAR 26.5X2.2 2
8 2125-410005-3A CUSHION COLLAR 1
9 2415-650001-10 RING BACK UP 40*35*15 1
10 0000-000132-00 ROD PACKING 30×40×6 1
11 3315-550006-00 CATCH 40X30X2 1
12 3525-413004-00 CUSHION COLLAR 1
13 2130-410003-00 COLLAR 21.5X2.2 1
BL-PDSR 30-0319 - 03-07-2019 12-87

DR_0032
Figure 12-40 Hydraulic Lines for Telescopic Lift Cylinder
12-88 BL-PDSR 30-0319 - 03-07-2019

HYDRAULIC LINES FOR TELESCOPIC LIFT CYLINDER
Qty.
Reqd.
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
BL-PDSR 30-0319 - 03-07-2019 12-89

DR_0033
Figure 12-41 Hydraulic Lines for Telescopic Mast
12-90 BL-PDSR 30-0319 - 03-07-2019

HYDRAULIC LINES FOR TELESCOPIC MAST
Qty.
Reqd.
1 2415-421000-00-01 HYDRAULIC LINE ASSEMBLY 1 Used for Lift Height 102”
1a 2415-421000-0A-03 HYDRAULIC LINE ASSEMBLY 1 Used for Lift Height 106”
1b 2415-421000-00-02 HYDRAULIC LINE ASSEMBLY 1 Used for Lift Height 126”
2 3316-610300-00 FITTING M14×1.5-M14×1.5 4
3 2415-424000-00-01 OIL PIPE 2 Used for Lift Height 102”
3a 2415-424000-0A-03 OIL PIPE 2 Used for 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 BOTTOM FIXED PLATE 1
9 0000-000028-00 SCREW M4×10 2
10 0000-000122-00 LOCKWASHER Ø4 2
11 0000-000089-00 FLATWASHER Ø4 2
12 2415-426000-00 HYDRAULIC LINE B 1
13 2415-425000-00 HYDRAULIC LINE A 1
14 2702-141400-00 CONNECTOR G1/4-M14×1.5 1
15 0000-000044-00 WASHER Ø14 2
BL-PDSR 30-0319 - 03-07-2019 12-91

DR_0034
Figure 12-42 Telescopic Drag Chain Assembly
12-92 BL-PDSR 30-0319 - 03-07-2019

TELESCOPIC DRAG CHAIN ASSEMBLY
Qty.
Reqd.
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
BL-PDSR 30-0319 - 03-07-2019 12-93

DR_0035
Figure 12-43 Windshield
12-94 BL-PDSR 30-0319 - 03-07-2019

WINDSHIELD
Qty.
Reqd.
1 0000-000277-00 BOLT M8×16 8
2 0000-000159-00 LOCKWASHER Ø8 8
3 0000-000176-00 FLATWASHER Ø8 12
4 0000-000550-00 NUT M8 4
5 2415-600007-00-01 WINDSHIELD 1
324200107 - Lift Height 102”
5a 2415-600007-0B-02 WINDSHIELD 1
325200481- Lift Height 106”
5b 2415-600007-0C-02 WINDSHIELD 1
325200482- Lift Height 106”
5c 2415-600007-0B-03 WINDSHIELD 1
325200481- Lift Height 126”
5d 2415-600007-0C-03 WINDSHIELD 1
325200482- Lift Height 126”
5e 2415-600007-0B-04 WINDSHIELD 1
325200481- Lift Height 157”
5f 2415-600020-1A-01 WINDSHIELD 1
325200482- Lift Height 157”
5g 2415-600020-1A-04 WINDSHIELD 1 Used for Lift Height 189”
6 2415-600008-00 WINDSHIELD BRACKET 4
325200481
6a 2415-600008-0A WINDSHIELD BRACKET 4
325200482
7 2214-150002-0A WASHER 8
BL-PDSR 30-0319 - 03-07-2019 12-95

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PDSR 30

POWER DRIVE REACH

Big Lift LLC MANUAL NO. BL-PDSR 30-0319 - 03-07-2019

Section Page Section Page

2 OPERATION ...............................................................2-1 6 BRAKE SERVICING ................................................... 6-1

BL-PDSR 30-0319 - 03-07-2019 1

9-2.8.3 INSTALLATION ................................. 9-18

1-2 BL-PDSR 30-0319 - 03-07-2019

1-1. INTRODUCTION. forks raised or lowered; however, the speed is restri-

The model number will be found on the name plate

1-2. GENERAL DESCRIPTION.

BL-PDSR 30-0319 - 03-07-2019 1-1

1-2 BL-PDSR 30-0319 - 03-07-2019

Figure 1-2 PDSR Lift Truck

Pos. Component Pos. Component

3 LIFT CYLINDER 9 STABILIZERS

4 KEY SWITCH 10 DRIVE WHEEL

5 BATTERY INDICATOR 11 BATTERY PLUG

6 EMERGENCY DISCONNECT 12 REACH ASSEMBLY

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2-1. GENERAL. • Avoid overhead wires and obstructions.

Figure 2-1 Load Center

Table 2-1 Operator Checks

ITEM PROCEDURE ITEM PROCEDURE

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Figure 2-2 Sample of Operator Check List

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2-8. LIFT AND LOWER CONTROLS

2-9. LOADING AND UNLOADING

Figure 2-6 Belly Button Switch

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3-1. GENERAL. CAUTION: Gases produced by a battery can be

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• Do not charge a frozen battery. if electrolyte is spilled or overflows from a cell, it

1. Charge the battery only in areas designated for

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Table 3-2 Recommended Lubricants (See Table 3-3 for Application)

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Figure 3-1 Lubrication Diagram

Full length of channel where rollers

4 Lift Chain Brush or Spray No. 4 See Paragraph 3-6

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4-1. GENERAL Operate:

Table 4-1. Troubleshooting Chart

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

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Truck travels forward and in reverse

TROUBLE WITH BRAKING

Check deadman switch for conti-

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a. Battery is dead or disconnected. Check and recharge if required.

b. Defective wiring. Check and repair as required.

TROUBLE WITH LIFTING OR

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4-2.2.2 Logbook Access

NOTE: Refer to bigjoesupport.com for the Zapi sup-

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