T15

PEDESTRIAN TUGGER

Operation
Maintenance
Repair Parts List

Big Lift LLC MANUAL NO. T15-0416 - 08-09-2018

www.bigjoeforklifts.com
Section Page Section Page

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

1-1 INTRODUCTION ........................................1-1 5-1 CONTROL HEAD .......................................5-1
1-2 GENERAL DESCRIPTION .........................1-1 5-1.1 CAP ASSEMBLY REMOVAL..............5-1
1-3 SAFETY FEATURES..................................1-1 5-1.2 CAP ASSEMBLY INSTALLATION......5-2
5-1.3 CONTROL HEAD REMOVAL.............5-3
2 OPERATION.......................................................2-1 5-1.4 CONTROL HEAD INSTALLATION.....5-3
2-1 GENERAL...................................................2-1 5-1.5 POTENTIOMETER REPLACEMENT .5-3
2-2 OPERATING PRECAUTIONS....................2-1 BELLY-BUTTON SWITCH
2-3 BEFORE OPERATION...............................2-1 5-1.6 REPLACEMENT .................................5-3
2-4 GENERAL CONTROL OPERATION..........2-3 5-1.7 HORN SWITCH REPLACEMENT ......5-4
2-5 DRIVING AND 5-2 COMPARTMENT COVERS .......................5-6
STOPPING PROCEDURES3 5-2.1 REMOVAL ..........................................5-6
2-5.1 STOPPING .........................................2-3 5-2.2 INSTALLATION ..................................5-6
2-6 BELLY-BUTTON SWITCH .........................2-4
2-7 COUPLING AND UNCOUPLING ...............2-4 6 DRIVING SYSTEM .............................................6-1
2-8 PARKING....................................................2-4 6-1 DRIVE WHEEL ...........................................6-1
6-2 TRANSMISSION ........................................6-2
3 PLANNED MAINTENANCE................................3-1 6-3 CASTER .....................................................6-3
3-1 GENERAL...................................................3-1
3-2 MONTHLY AND QUARTERLY CHECKS...3-1 7 ELECTRICAL COMPONENTS...........................7-1
3-3 BATTERY CARE ........................................3-1 7-1 ELECTRICAL CONTROL PANEL ..............7-1
3-3.1 GENERAL...........................................3-1 7-1.1 MAINTENANCE..................................7-1
3-3.2 SAFETY RULES .................................3-2 7-1.2 CLEANING..........................................7-1
3-3.3 BATTERY CARE AND CHARGING ...3-2 7-1.3 CONTROLLER REMOVAL.................7-1
3-3.4 BATTERY CLEANING ....................... 3-2 7-1.4 CONTROLLER INSTALLATION.........7-1
3-4 CHARGING BATTERIES ...........................3-2 7-1.5 CHARGER REMOVAL .......................7-1
3-5 BATTERIES REPLACEMENT....................3-3 7-1.6 CHARGER INSTALLATION ...............7-1
7-1.7 BUZZER REMOVAL ...........................7-4
4 TROUBLESHOOTING........................................4-1 7-1.8 BUZZER INSTALLATION ...................7-4
4-1 GENERAL...................................................4-1 7-1.9 KEY SWITCH REMOVAL ...................7-4
4-2 CONTROLLER TROUBLESHOOTING ......4-2 7-1.10 KEY SWITCH INSTALLATION ...........7-4
4-2.1 FAULT DETECTION...........................4-2 7-1.11 BATTERY INDICATOR REMOVAL ....7-4
HAND HELD PROGRAMMER BATTERY INDICATOR
4-2.2 (OPTIONAL) .......................................4-2 7-1.12 INSTALLATION ..................................7-4
4-2.3 FAULT RECORDING..........................4-2 7-1.13 LED INDICATOR REMOVAL.............7-4
4-2.4 GENERAL CHECKOUT......................4-2 7-1.14 LED INDICATOR INSTALLATION.....7-4
4-2.5 DIAGNOSTIC HISTORY.....................4-4 EMERGENCY DISCONNECT
TEST THE FAULT 7-1.15 REMOVAL ..........................................7-4
4-2.6 DETECTION CIRCUITRY...................4-4 EMERGENCY DISCONNECT
DIAGNOSTICS AND 7-1.16 INSTALL. ...........................................7-5
4-2.7 TROUBLESHOOTING........................4-4
4-2.7.1 LED DIAGNOSTICS ......................4-4 8 OPTIONAL EQUIPMENT ...................................8-1
4-2.8 PROGRAMMER DIAGNOSTICS........4-4 8-1 HOOK .........................................................8-1

9 ILLUSTRATED PARTS BREAKDOWN..............9-1

T15-0416 - 08-09-2018 1
1-2 PDM0495
 SECTION 1
DESCRIPTION

1-1. INTRODUCTION
This publication describes the 24 volt tow truck
distributed by Big Lift LLC. Included are operating
instructions,planned maintenance instructions,
lubrication procedures, corrective maintenance
procedures and a complete parts list with part
location illustrations.
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 T-15 tow truck.

1-2. GENERAL DESCRIPTION

The tow truck, Figure 1-2, transports payloads up to
2200 pounds on level surfaces.
The forward and reverse motion is controlled by
Figure 1-1 Name Plate
either of two controller levers mounted on the control
head.Stopping and turning is controlled by the • Belly-button switch to reverse truck should the ope-
steering arm. The battery powered tow truck is quiet rator accidentally pin himself against a wall or obst-
and without exhaust fumes. ruction when backing up in slow speed.
The reversible DC motor propels the tow truck in • All control functions automatically return to “OFF”
forward or reverse direction throughout the available when released.
speed range. • Externally accessible battery disconnect within
The model number will be found on the name plate operator's reach.
(Figure 1-1) along with the capacity. Figure 1-2 • Separately fused control circuits and power circuits.
shows the locations of the truck’s main components
and controls. • Readily accessible horn button.
• Handle to provide a firm hand hold for operator.
1-3. SAFETY FEATURES
• High visibility color scheme of truck provides visual
The T-15 is designed engineered to provide maximum alert of truck’s presence.
safety for operator and payload. Some of the safety
features incorporated into the design are • Battery Indicator.
• Balance wheels.

T15-0416 - 08-09-2018 1-1

 Figure 1-2 Tugger Overview
Table 1-1Tugger Overview

ITEM COMPONENT ITEM COMPONENT

1 Driving unit 8 Battery discharge indicator

2 Trailer coupling 9 Handwheel

3 Battery 10 Control handle

4 Cover 11 Plug

5 Key switch 12 Casters

6 Emergency brake switch 13 Driving wheels

7 LED light

1-2 T15-0416 - 08-09-2018

 SECTION 2
OPERATION

2-1. GENERAL • When attaching and uncoupling trailers the tow

This section gives detailed operating instructions for • truck and trailer must be on level ground.All con-
the tow truck. The instructions are divided into the trols must be set to neutral.
various phases of operations, such as operating, • The tow truck and trailer must be secured to prevent
driving and stopping. Routine precautions are any accidental movement.
included for safe operation. • Trailer trains are difficult to shunt. For this reason
make sure the angle is correct when cornerning.
2-2. OPERATING PRECAUTIONS

WARNING: Improper operation of the tow truck may 2-3. BEFORE OPERATION
result in operator injury, or load and/or Table 2-1 covers important inspection points on the
tow truck damage. Observe the fol- T-15 tow truck which should be checked prior to
lowing precautions when operating the operation.Depending on use, some trucks may
tow truck. require additional checks.
• The following safety precautions must be adhered to Figure 2-1 shows a sample format for an Operator
at all times. Checklist, which can be modified as necessary to fit
your operation.
• Do not operate this truck unless you have been
trained and authorized to do so. WARNING: Periodic maintenance of this truck by a
• All warnings and instructions must be read and QUALIFIED TECHNICIAN is required.
understood before using the equipment.
• Equipment must not be altered in any way.
CAUTION: A QUALIFIED SERVICE TECHNICIAN
• Equipment must be inspected by a qualified person should check the truck monthly for
on a regular basis. proper lubrication, proper fluid levels,
• Do not exceed the rated capacity. Overloading may brake maintenance, motor maintenance
result in damage to the driving system and struct- and other areas specified in the SEC-
ural components. TION 3.

• Always pull, never push a trailer. WARNING: If the truck is found to be unsafe and in
need of repair, or contributes to an
• Be sure the truck has a firm and level footing.
unsafe condition, report it immediately to
• Avoid overhead wires and obstructions. the designated authority. Do not operate
• Check for obstructions when traveling with trailers. it until it has been restored to a safe
operating condition. Do not make any
• Do not handle unstable or loosely stacked loads. unauthorized repairs or adjustments. All
Use special care when handling long, high, or wide service must be performed by a qualified
loads to avoid tipping, loss of load, or striking bysta- maintenance technician.
nders.

Table 2-1Operator Checks

ITEM COMPONENT ITEM COMPONENT

Safety Check that warning labels, nameplate, etc., Wheels Check drive wheel for cracks or dam-
signs are in good condition and legible. age. Move truck to check load for free-
dom of rotation.

Horn Check that horn sounds when operated. Emer- Check that emergency stop switch can
gency be disengaged and reengaged.
Stop
Switch

Travel Check that speed controls on control head Battery Check the battery indicator.
controls operate in all speed ranges in forward and charge
reverse and that belly button switch func-
tions.

T15-0416 - 08-09-2018 2-1

 Figure 2-1 Sample of Operator Check List

2-2 T15-0416 - 08-09-2018

2-4. GENERAL CONTROL OPERATION 2-5. DRIVING AND STOPPING PROCEDURES
The speed control (See Figure 2-2) located on each 1. Connect the battery and turn on the key switch.
side of the control head provides fingertip control for Grasp the grips of the steering head so that the
driving the truck. Rotate the control in the direction you speed control can be comfortably operated by
want to travel. The farther you rotate the control from either thumb.
the neutral position, the faster the truck will travel. 2. To move forward (with load in back), slowly press
the speed control forward. See Figure 2-2. Press
the forward speed control farther to increase
speed.
3. To slow down or stop, release the speed control
4. Procedures for movement in reverse are the
same as in the forward direction except slowly
press the speed control backward. See Figure 2-
2.

2-5.1. STOPPING
The stopping distance of the truck depends on the
ground conditions. The driver must take this into
account when operating the truck.
The driver must be looking ahead when traveling. If
Figure 2-2 Forward/Reverse Control there is no hazard, brake moderately to avoid moving
the load.
The pushbutton switches (See Figure 2-3), located on
the front of the control head activate the lift-lower con- There are three different ways to stop the truck:
trols and the horn. 1. Plugging: This electrical braking function con-
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 opera-
tion. If the control is not released, the truck will
accelerate in the opposite direction.
2. Emergency braking: Press the emergency brake
switch, all electrical functions are cut out and the
truck automatically brakes.
3. Regenerative braking: If the speed control lever
is released, the truck automatically brakes regen-
eratively.When the speed is below.5 MPH, the
brake applies.

Figure 2-3 Pushbutton Switch

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2-6. BELLY-BUTTON SWITCH 2-7. COUPLING AND UNCOUPLING
The belly-button switch (Figure 2-4) minimizes the 1. Move truck to location where trailer is to be picked
possibility of the driver being pinned by the steering up.
arm while driving the lift truck in slow speed. If the 2. Move the truck into position so the trailer is into
switch presses against the operator while the lift the trailer coupling.
truck is being driven toward the operator, the switch
changes the direction of the lift truck. 3. Drive to area where trailer is to be placed.
4. 5. Uncoupling the trailer, slowly move the truck
out from the trailer.

2-8. PARKING
When finished with moving trailers, 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,
SECTION 3.

2-4 T15-0416 - 08-09-2018

 SECTION 3
PLANNED MAINTENANCE

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

Planned maintenance consists of periodic visual and explosive. Do not smoke, use an open
operational checks, parts inspection, lubrication, and flame, create an arc or sparks in the
scheduled maintenance designed to prevent or vicinity of the battery. Ventilate an
discover malfunctions and defective parts. The enclosed area well when charging.
operator performs the checks in SECTION 2, CAUTION: Batteries contain sulfuric acid which may
and refers any required servicing to a qualified cause severe burns. Avoid contact with
maintenance technician who performs the scheduled eyes, skin or clothing. In case of contact,
maintenance 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 tow 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
case can cause misleading trouble symptoms with
performed by a qualified service technician or your
the truck electrical system. Since components of
Big Lift LLC Service Representative.
the truck electrical system are insulated from truck
frame, leakage voltage will not normally affect truck
3-3. BATTERY CARE
operation unless a short circuit or breakdown of
3-3.1. GENERAL circuit wire insulation to truck frame occurs.

The T-15 may be equipped with maintenance free or A voltage check from battery connector terminal
industrial wet cell batteries. to battery case should indicate near zero volts.
The care and maintenance of the battery is very Typically, however, the sum of the voltages at both
important to obtain efficient truck operation and terminals will equal battery volts. This leakage
maximum battery life. voltage will discharge the battery. As battery
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.
Monthly Check casters for wear. A poly load wheel must be replaced if worn to within 1/16
inch of hub. Check for separation from hub.
Monthly Check drive wheel for wear. A poly drive wheel must be replaced if worn to within 3/4
inch of hub. Check for separation from hub.
Monthly Inspect wiring for loose connections and damaged insulation.

T15-0416 - 08-09-2018 3-1

3-3.2. SAFETY RULES 4. Before connecting the battery cable to the trucks
• Wear protective clothing, such as rubber apron, receptacle, make sure the key switch is off. The
gloves, boots and goggles when performing any battery cable must be fully connected before the
maintenance on batteries. Do not allow electrolyte truck is used. If the plug is not making good con-
to come in contact with eyes, skin, clothing or floor. If tact, heat will weld the two parts of the battery
electrolyte comes in contact with eyes, flush connector together, making it difficult to remove
immediately and thoroughly with clean water. and necessary to replace.
Obtain medical attention immediately. Should 5. Battery terminals should be checked and cleaned
electrolyte be spilled on skin, rinse promptly with of corrosion regularly. Good battery terminal con-
clean water and wash with soap. A baking soda tact is essential not only for operation, but also for
solution (one pound to one gallon of water) will proper charging of the battery.
neutralize acid spilled on clothing, floor or any 6. The charging requirements will vary depending on
other surface. Apply solution until bubbing stops the use of the truck. The battery should be given
and rinse with clean water. as equalizing charge on a weekly basis. This
• If truck is equipped with wet cell batteries, keep vent charge should normally be an additional three
plugs firmly in place at all times except when adding hours at the finish rate.
water or taking hydrometer readings. Do not allow 7. Make certain battery used meets weight and size
dirt, cleaning solution or other foreign material to requirements of truck. NEVER operate truck with
enter cells. Impurities in electrolyte has a neutraliz- an undersized battery.
ing effect reducing available charge.
3-3.4. BATTERY CLEANING
• Do not bring any type of flame, spark, etc., near the
battery. Gas formed while the battery is charging, is Always keep vent plugs tightly in place when
highly explosive. This gas remains in cell long after cleaning battery. When properly watered and
charging has stopped. charged, the battery will remain clean and dry. All
that is necessary is to brush or blow off any dust
• Do not lay metallic or conductive objects on battery.
or dirt that may accumulate on them. However, if
Arcing will result.
electrolyte is spilled or overflows from a cell, it
• Do not touch non-insulated parts of DC output should be neutralized with a solution of baking soda
connector or battery terminals to avoid possible and water, brushing the soda solution beneath the
electrical shock. connectors and removing grime from the covers.
• De-energize all AC and DC power connections Then rinse the battery with cool water from a low
before servicing battery. pressure supply to remove the soda and loosen dirt. If
batteries stay wet consistently, they may be either
• Do not charge a frozen battery. overcharged or over filled. This condition should be
• Do not use charger if it has been dropped or oth- investigated and corrected.
erwise damaged.
3-4. CHARGING BATTERIES
3-3.3. BATTERY CARE AND CHARGING
Charging requirements will vary depending on depth
CAUTION: Never smoke or bring open flame near of discharge and temperature. Follow safety rules
the battery. Gas formed during charging when placing a battery on charge.
is highly explosive and can cause seri- Proceed as follows:
ous injury.
1. Park truck at charging station and turn the key
1. Charge the battery only in areas designated for switch off.
that use. 2. Check the condition of the AC cord and battery
2. Make certain the charger being used matches the cables. If there are any cuts in the cable, any
voltage and amperage of the truck battery. exposed wires, loose plugs or connectors, DO
3. Before disconnecting or connecting batteries to a NOT attempt to charge the batteries. Contact
charger, make sure the charger is “OFF”. If an appropriate personnel for repairs to be made.
attempt is made to do this while the charger is 3. Pull the charger cord out of the cover (1, Figure 3-
“ON”, serious injury to you, the battery and the 1) and connect to the appropriate power supply.
charger could result.

3-2 T15-0416 - 08-09-2018

4. The LED (2) produces a permanent red light to
indicate that the charger is connected.
a. Remove four screws(1)and remove the covers(2).
5. Charge the batteries until the LED (2) produces a
permanent green light.
6. Disconnect the charger cord and insert it in its
receptacle on the truck.

Figure 3-2 Cover Removal

b. Remove two screws (3) and the battery plate (4).

Figure 3-1 Battery Charging

3-5. BATTERIES REPLACEMENT

Access to the batteries requires moving the Charging
requirements will vary depending on depth of
discharge and temperature. Follow safety rules when
placing a battery on charge.

CAUTION: Park the truck securely and turn off

the power before removal and installa-
tion battery.

Proceed as follows:

Figure 3-3 Screw Removal

c. Tag and disconnect the three battery cables.
d. Replace batteries.

T15-0416 - 08-09-2018 3-3

 NOTES

3-4 T15-0416 - 08-09-2018

 SECTION 4
TROUBLESHOOTING

4-1. GENERAL Truck Will Not Operate:

Use Table 4-1 as a guide to determine possible Truck Does Not Operate Forward or Reverse:
causes of trouble. The table is divided into three
Trouble With Braking:
main categories:
Table 4-1Table 4-1 Troubleshooting Chart
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TRUCK WILL NOT OPERATE a. Fuse (2, Figure 7-2) blown. Check fuse and replace if necessary.
b. Fuse (10, Figure 7-1) blown. Check fuse and replace if necessary.
Truck will not work.
c. Battery dead or disconnected. Check battery connections and
check battery voltage.
d. Key switch (5, Figure 7-1) defective.Bypass key switch to determine if it
is malfunctioning.
e. Emergency brake switch (1, Figure
7-1) defective. Bypass the switch to determine if it is
f. Defective wiring. malfunctioning.
Check for open circuit. Repair as

TRUCK DOES NOT OPERATE

FORWARD OR REVERSE

Truck does not travel forward or a.Check all wiring. A loose connec- Tighten all loose connections before
reverse. All other functions operate tion may be the cause of malfunction. further troubleshooting.
normally.

b.Defective main controller (20, Fig- Check for proper operation and
ure 7-1). replace if necessary.
c.Defective potentiometer (21, Figure Check and replace potentiometer if
5-1). defective.

Defective potentiometer (21, Figure Check and replace potentiometer if

Truck travels forward but not in
5-1) in control head. defective.
reverse.
Defective potentiometer (21, Figure Check and replace potentiometer if
Truck travels reverse but not in for-
5-1) in control head. defective.
ward.
Defective potentiometer (21, Figure Check and replace potentiometer if
Truck travels forward and in
5-1) in control head. defective.
reverse at lower speeds; will not
travel at high speed.

T15-0416 - 08-09-2018 4-1

 Table 4-1Troubleshooting Chart- Continued
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
TROUBLE WITH BRAKING
Truck does not slow with brake, or Defective electric brake (12, Fig- Adjust or replace brake.
brake does not engage. ure 6-1).

Brake will not release. a. Defective electric brake (12, Replace.

Figure 6-1). Allow to cool and check air gap.
b. Brake temperature above 281° F
(140° C).
c. Open brake circuitry or wiring. Make voltage checks. Replace.
Defective electric brake (12,
Brake drags.
Figure (6-1).

Brake grabs. a. Incorrect stopping distance Adjust.

adjustment.
b. Defective electric brake (12, Fig- Replace.
ure 6-1).
Replace.
Abnormal noise and chatter when Defective electric brake (12, Figure
brake is applied. 6-1).

4-2. CONTROLLER TROUBLESHOOTING 4-2.4 GENERAL CHECKOUT

4-2.1 FAULT DETECTION Carefully complete the following checkout procedure. If

you find a problem during the checkout, refer to
The controller provides diagnostics information to paragraph 4-2.7. for further information.
assist technicians in troubleshooting drive system
problems. When a fault is detected, the appropriate The checkout can be conducted with or without the
fault code is signaled via the panel mounted LED. handheld programmer (See Paragraph 4-2.2.).How-
ever, the checkout procedure is easier with a progra-
4-2.2 HAND HELD PROGRAMMER (OPTIONAL) mmer. To evaluate the system without a programmer,
observe the LED and note the flashing pattern and
The hand held programmer is available that is
refer to Table 4-2 for the code description.
designed specifically for use with the controller. The
programmer is available through your Big Lift LLC CAUTION: Put the vehicle up on blocks to get the
dealer. drive wheel off the ground before begin-
ning these tests.
4-2.3 FAULT RECORDING
Fault events are recorded in the controller's memory. Turn the keyswitch off and make sure the
However, multiple occurrences of the same fault are brake is applied, the throttle is in neutral,
recorded as one occurrence. and the forward/reverse switches are
open.
The fault event list can be loaded into the program-
mer for readout. The Special Diagnostics mode Do not stand, or allow anyone else to
provides access to the controller's diagnostic history stand directly in front of or behind the
file. The history file contains the entire fault event vehicle during the tests.
list created since the diagnostic history file was last
cleared. The standard Diagnostics mode provides
information about only the currently active faults.

4-2 T15-0416 - 08-09-2018

1. Disconnect the battery charger and connect the of the Arrow Keys. Press the Right side of the
programmer to the 4-pin connector (Figure 4-1) Arrow Keys again to display the list of System
on the controller. Faults. The display should indicate "No Known
Faults."
Release the brake by pulling down the
steering arm into the operating position. The
controllers LED should continue blinking a
single flash and the programmer should
continue to indicate no faults. If there is a
problem, the LED will flash a diagnostic code
and the programmer will display a diagnostic
message. If you are conducting the checkout
without a programmer, look up the LED
Figure 4-1 Controller Terminals diagnostic code in Table 4-3.
2. Turn the lift truck key switch to the ON position. When the problem has been corrected, it may
The programmer should "power up" with an initial
be necessary to cycle the brake in order to clear
display (Figure 4-2), and the controllers Status
the fault code.
LED should begin steadily blinking a single flash.
If neither happens, check for continuity in the key 4. With the brake released, select a direction and
switch circuit and controller ground. operate the throttle. The motor should begin to
turn in the selected direction. If it does not, verify
the wiring to the forward/reverse switches and
motor. The motor should run proportionally faster
with increasing throttle. If not, refer to Paragraph
4-2.7.
5. Put the controller into the test mode by using the
Arrow Keys to select the "Monitor" menu.
Select the Monitor mode by pressing the "Right"
arrow on the Arrow Keys. Press the Arrow key
"Down" arrow to scroll down to observe the
status of the forward, reverse, brake, emergency
reverse, and mode switches. Cycle each switch in
turn, observing the programmer. Each input
should show the correct state on the programmer.
6. Check the controller's fault detection circuitry as
described in Paragraph 4-2.5.
7. Take the vehicle off the blocks and drive it in a
clear area. It should have smooth acceleration
and good top speed.
8. Test the plug braking of the vehicle. The vehicle
should smoothly slow to a stop and reverse direc-
tion, with the audible plugging tone.
9. Verify that all options, such as high pedal disable
(HPD), static return to off (SRO), and anti-tiedown,
are as desired.
10. Check to see whether the emergency reverse
(belly button) feature is working correctly. Verify
Figure 4-2 Hand Held Programmer that the circuit is operational by momentarily dis-
3. Put the controller into the diagnostic mode by connecting one of the emergency reverse wires.
pressing the "Arrow Keys" (Figure 4-2). Using The vehicle should be disabled and a fault indi-
the Navigation key, select the Faults menu. Dis- cated.
play the Faults menu by pressing the Right side

T15-0416 - 08-09-2018 4-3

4-2.5 DIAGNOSTIC HISTORY 6. Cycle the key switch off and on. Release the
The handheld programmer can be used to access brake and apply the throttle. The vehicle should
the controller's diagnostic history file. When the prog- now operate normally.
rammer is connected to the unit, the error log 4-2.7 DIAGNOSTICS AND TROUBLESHOOTING
file is automatically uploaded into the handheld
programmer. The motor controller provides diagnostics information
to assist in troubleshooting drive system problems.
To see the present status of the unit, use the Arrow The diagnostics information can be obtained in two
Keys ( Figure 4-2) to select: ways:
Faults->System Faults. • Reading the appropriate display on the programmer.
To access this log, use the Arrow Keys to select: • Observing the fault codes issued by the panel
Faults->Fault History. mounted Status LED.
The faults are shown as a code and descriptive text. If
there are multiple faults, you have to scroll through the 4-2.7.1 LED Diagnostics
list using the Up and Down Buttons on the Arrow During normal operation with no faults present, the
Keys. Status LED is steady on. If the controller detects a
The faults may be intermittent faults, faults caused fault the Status LED flashes a fault identification
by loose wires, or faults caused by operator errors. code continuously until the fault is corrected.
Faults such as HPD or over-temperature may be NOTE: The Status LED can only indicate one fault at
caused by operator habits or by overloading. a time. If multiple faults are detected, the
After a problem has been diagnosed and corrected, highest priority fault code flashes until it is
clearing the diagnostic history file is recommended. cleared.
This allows the controller to accumulate a new file of
faults. By checking the new diagnostic history file at a With Fault Code Type parameter is set to 0, the status
later date, you can quickly determine whether the LED uses the fault codes listed in Table 4-2. Six sin-
problem has been completely fixed. gle-digit codes are used: 2, 3, 5, 6, 7, and 9.

To clear the diagnostic history file, select: Faults- For suggestions about possible causes of the various
>Clear Fault History. faults, refer to Table 4-3 Troubleshooting Chart.

You will be asked to confirm your actions. Use the 4-2.8 PROGRAMMER DIAGNOSTICS
"plus" arrow (+) for yes to clear the menu and the
With a programmer, diagnostics and troubleshooting
"minus" arrow (-) to cancel your selection and not
is more direct than with the LED alone. The program-
clear the Fault History.
mer presents complete diagnostic information in
4-2.6 TEST THE FAULT DETECTION CIRCUITRY plain language - no code to decipher. Faults are
displayed in the Diagnostic Menu, and the status of
1. Put the vehicle up on blocks to get the drive wheel the controller inputs/outputs is displayed in the Test
off the ground. Menu.
2. Engage the emergency brake switch (1, Figure The following 4-step process is generally used for
10-1) and turn off key switch (5). diagnosing and troubleshooting an inoperative
3. Using an inline fuse holder fitted with a 10 amp vehicle using the programmer:
fuse and alligator clips, connect the controller's M
1. Visually inspect the vehicle for obvious problems:
and B- terminals.
2. Diagnose the problem:
4. Disengage the emergency brake switch (1, Figure
10-1) and turn on key switch(5). 3. Test the circuitry with the programmer:
5. Leave the key switch on and remove the in-line 4. Correct the problem.
fuse wire. The vehicle status should continue to Repeat the last three steps as necessary until the
remain off. vehicle is operational.
Refer to the Table 4-3 for suggestions covering a
wide range of possible faults.

4-4 T15-0416 - 08-09-2018

 Table 4-2LED Codes
LED Code Explanation
LED Off Not illuminated No power or defective controller
Solid On Always on Controller operational, no faults
2 00 Undervoltage Fault
3 000 Overvoltage Fault
5 00000 Brake ON Fault
HPD Fault
6 000000 Wiring Fault *
Speed Pot Fault
7 0000000 Throttle Fault
Battery Disconnect Fault*
Brake OFF Fault
Current Sense Fault*
EE Checker Fault†
Hardware Failsafe*
9 000000000
Main Fault*
Main OFF Fault
Main ON Fault

* = Must cycle keyswitch to clear

† = Must use programmer to clear, as follows: select Program menu,

alter data value of any parameter, cycle keyswitch.

Table 4-3Troubleshooting Chart

LED PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE
CODE LCD DISPLAY
Battery Disconnect 1. Battery not connected.
9 Fault Battery disconnected
2. Poor connection to battery terminals.
1. Electromagnetic brake driver open.
9 Battery OFF Fault Brake OFF Fault
2. Electromagnetic brake coil shorted.
1. Electromagnetic brake driver shorted.
5 Brake ON Fault Brake ON fault
2. Electromagnetic brake coil open.
1. Short in motor on in motor willing.
9 Current Sense Fault Current sense out of range
2. Controller failure. *
9 EEPROM Checksum EEPROM fault EEPROM failure or fault
Fault

T15-0416 - 08-09-2018 4-5

 Table 4-3Troubleshooting Chart- Continued
LED PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE
CODE LCD DISPLAY
1. Motor voltage does not correspond to
throttle request.

9 Hardware Failsafe Motor voltage out of range 2. Short in motor or in motor wiring.

3. Controller failure.*
1. Improper sequence of throttle and
KSI, push or inhibit pot.
6 HPD Fault HPD (High Pedal Disable)
2. Misadjusted throttle pot.
1. Main contractor welded or stuck open.
9 Main Fault Main contactor fault
2. Main contactor driver fault.
9 Main OFF Fault Main contactor driver Off fault Main contactor driver failed open.
9 Main ON Fault Main contactor driver On fault Main contactor driver failed closed.

1. Battery voltage >31 volts.

2. Vehicle operating with charger

3 Overvoltage Fault Battery voltage too high attached.

3. Intermittent battery connection.

1. Brake driver shorted.

9 Precharge Fault Precharge fault

2. Precharge circuit damaged.

3. MOSFET failure.
1. Speed limit pot wire(s) broken or
Speed limit pot wiper out of shoted.
7 Speed POT Fault range
2. Broken speed limit pot.
1. Throttle input wire open or shorted.
PotLow and /or PotWiper out of 2. Throttle pot defective.
7 Throttle Fault range
3. Wrong throttle type selected.
1. Battery voltage <17 volts.

2 Undervoltage Fault Battery voltage too low 2. Bad connection at battery or controller.

1. Misadjusted throttle.

6 Wiring Fault HPD fault present >10 sec. 2. Broken throttle pot or throttle
mechanism.

4-6 T15-0416 - 08-09-2018

 Figure 4-3 Wiring Diagram

T15-0416 - 08-09-2018 4-7

 NOTES

T15-0416 - 08-09-2018 4-9

 SECTION 5
CONTROL HEAD

5-1. CONTROL HEAD 1. Engage the emergency break switch and turn off
key switch.
5-1.1 CAP ASSEMBLY REMOVAL
2. Remove four screws, lift up cap assembly and
disconnect harness from harness.

Figure 5-1Control Head

T15-0416 - 08-09-2018 5-1

5-1.2 CAP ASSEMBLY INSTALLATION 2. Position cap assembly on control head and secure
1. Hold cap assembly in place and connect harness with four screws.
to harness. 3. Disengage the emergency brake switch and turn on
key switch.

Figure 5-2Figure 5-2 Steering Arm

5-2 T15-0416 - 08-09-2018

5-1.3 CONTROL HEAD REMOVAL 5. Remove screw, lock washer and flat washer.
1. Remove the cap assembly as described in para- 6. Remove screw, lock washer and flat washer
graph 5-1.1. and remove potentiometer from bracket.
2. Disconnect harness from potentiometer and 7. Position new potentiometer in bracket and
switch assembly. secure with screw, lock washer and flat washer
3. Remove two screws, two lock washers and two 8. Install screw, lock washer and flat washer.
flat washers. 9. Install control knob on potentiometer and secure
with screw and washer.
WARNING: When removing the control head in the
following steps, be sure to hold it in place 10. Install control knob on the other side of potentiom-
until the control harness is disconnected. eter and secure with screw and washer.
11. Connect harness to potentiometer.
4. Remove two screws, two washers and two flat
washers. 12. Install the cap assembly as described in para-
graph 5-1.2.
5. Remove the control head and handle.
5-1.6 BELLY-BUTTON SWITCH REPLACEMENT
5-1.4 CONTROL HEAD INSTALLATION
1. Remove the cap assembly as described in para-
1. Hold control head and handle in place and install
graph 5-1.1.
two screws, two washers and two flat washers.
2. Disconnect harness from switch assembly.
2. Install two screws, two lock washers and two flat
washers. 3. Remove screw, lock washer and flat washer.
3. Reconnect harness to potentiometer and switch 4. Remove screw, lock washer and flat washer
assembly. and remove switch assembly from bracket.
4. Install the cap assembly as described in para- 5. Remove pin, bracket and spring from button.
graph 5-1.2. 6. Remove two pins and reversing switch from
bracket.
5-1.5 POTENTIOMETER REPLACEMENT
7. Position the new reversing switch in bracket and
1. Remove the cap assembly as described in para-
secure with two pins.
graph 5-1.1.
8. Position bracket in button and install pin.
2. Disconnect harness from potentiometer .
9. Position switch assembly on bracket and
3. Remove screw, washer and control knob from
secure with two screws.
potentiometer.
10. Reconnect harness to switch assembly.
4. Remove screw, washer and control knob from
other side of potentiometer. 11. Install the cap assembly as described in para-
graph 5-1.2.

T15-0416 - 08-09-2018 5-3

 Figure 5-3Figure 5-3 Emergency Reverse Switch Assembly

5-1.7 HORN SWITCH REPLACEMENT 4. Position the new switch in bracket and
secure with two pins.
1. Remove the cap assembly as described in para-
graph 5-1.1. 5. Position horn switch assembly in cover and
secure with three screws.
2. Remove three screws, bracket and springs.
6. Install the cap assembly as described in para-
3. Remove two pins and defective switch from
graph 5-1.2.
bracket.

5-4 T15-0416 - 08-09-2018

 Figure 5-4Cap Assembly

T15-0416 - 08-09-2018 5-5

5-2. COMPARTMENT COVERS

5-2.1 REMOVAL
1. Engage the emergency break switch and turn off
key switch.
2. Pull up the charger cable and remove cap from the
cable. Let cable back down into back cover.
3. Remove four screws.
4. Remove front cover and back cover.

5-2.2 INSTALLATION
1. Pull up the charger cable through the back cover
Install the cap.
2. Install front cover and back cover with four
screws.
3. Disengage the emergency break switch and
turn on key switch.

Figure 5-5 Compartment Cover

5-6 T15-0416 - 08-09-2018

 SECTION 6
DRIVING SYSTEM

6-1. DRIVE WHEEL 4. Remove the screw, nut, Axle, inner hub and outer
hub. Remove the inner tire from the outer tire.
1. Engage the emergency stop switch and turn off
key switch. 5. Inspect inner tire and replace if necessary.
2. Jack up the truck so the drive wheel is off the 6. Install new drive wheel in reverse order of
ground; then securely block the truck to prevent removal.
movement. 7. Disengage the emergency stop switch and turn
3. Remove the nut, and drive wheel assembly from on key switch.
transmission.

Figure 6-1Figure 6-1 Transmission, Motor, Brake Mounting

T15-0416 - 08-09-2018 6-1

6-2. TRANSMISSION 4. Disconnect cables from drive motor.
1. Engage the emergency break switch and turn off 5. Remove four screws, four lock washers fixed
key switch. block and transmission from frame.
2. Remove the compartment covers as described in 6. Remove the drive wheel assembly as described
paragraph 5-2. in paragraph 6-1.
3. Disconnect harness from the break. 7. Install new transmission by reversing the steps
above.

Figure 6-2Figure 6-2 Frame System

6-2 T15-0416 - 08-09-2018

6-3. CASTER 4. Remove four screws(7, Figure 6-2) , four lock
washers (8), four nuts (9) and caster (6).
1. Engage the emergency break switch (1, Figure
10-1) and turn off key switch (5). 5. Install new caster by reversing the steps above.
2. Block the drive wheels to prevent the truck from NOTE: Inspect the caster. If the caster is worn within
rolling. 1/8" of the metal sleeve,or is cracked or
3. Jack up the frame to raise the casters off the damaged,replace the entire caster.We recom-
floor. Securely block the frame in the raised posi- mend that both casters be replaced at the
tion by positioning supports under the frame. same time. This ensures level and safe oper-
ation of the truck.

T15-0416 - 08-09-2018 6-3

 NOTES

6-4 T15-0416 - 08-09-2018

 SECTION 7
ELECTRICAL COMPONENTS

7-1. ELECTRICAL CONTROL PANEL 3. Tag and disconnect main harness from controller.
4. Remove two screws,t wo lock washers and
7-1.1. MAINTENANCE
remove controller from bracket.
NOTE: Erratic operation of the truck may be caused
by defective controller components. Before 7-1.4. CONTROLLER INSTALLATION
removing the electrical panel, perform trou- 1. Position controller on bracket and secure with two
bleshooting procedures per SECTION 4, to screws and two lock washers.
determine corrective action to be taken.
2. Reconnect main harness to controller.
There are no user-serviceable parts inside the con- 3. Install the compartment covers as described in
troller. No attempt should be made to open the paragraph 5-2.
controller. Opening the controller may damage it and
4. Disengage the emergency brake switch and turn
will void the warranty.
on key switch.
The controller is programmed at the factory specifi-
cally for the truck model on which it is equipped. It is 7-1.5. CHARGER REMOVAL
important to replace the controller with the correct 1. Engage the emergency brake switch and turn off
preprogrammed unit to assure proper performance key switch.
settings intended for that particular truck. See Figure
2. Remove the compartment covers as described
7-1 for the preprogrammed controller number.
in paragraph 5-2.
It is recommended that the controller exterior be 3. Tag and disconnect main harness from charger.
cleaned periodically, and if a hand held programmer is
available, this periodic cleaning provides a good 4. Tag and disconnect remaining two charger leads
opportunity to check the controller’s diagnostic from the batteries.
history file. It is also recommended that the 5. Disconnect remaining three charger leads from
controller’s fault detection circuitry be checked the winding roll.
whenever the vehicle is serviced. 6. Remove four screws, four lock washers, four
7-1.2. CLEANING flat washers and two hoops. Remove charger
from bracket.
1. Engage the emergency brake switch and turn off
key switch.
2. Remove the covers as described in paragraph 5-2. 7-1.6. CHARGER INSTALLATION
3. Remove any dirt or corrosion from the bus bar 1. Position charger on bracket and secure with
area. The controller should be wiped clean with a four screws and four lock washers, four flat
moist rag. Allow it to dry before reconnecting the washers and two hoops.
battery.
2. Reconnect the two charger leads to the batteries.
4. Make sure the connections to the buss bars are
tight.Use two well insulated wrenches for this task 3. Reconnect the three charger leads to the winding
in order to avoid steering the buss bars. roll.

7-1.3. CONTROLLER REMOVAL 4. Reconnect main harness to charger.

1. Engage the emergency brake switch and turn off 5. Install the compartment covers as described in
key switch. paragraph 5-2.
2. Remove the covers as described in paragraph 5-2. 6. Disengage the emergency brake switch and turn
on key switch.

T15-0416 - 08-09-2018 7-1

 Figure 7-1Figure 7-1 Electrical System

7-2 T15-0416 - 08-09-2018

 Figure 7-2 Wiring Harness

T15-0416 - 08-09-2018 7-3

7-1.7. BUZZER REMOVAL 4. Remove mounting nuts and bracket and remove
battery indicator from the bracket.
1. Engage the emergency brake switch and turn off
key switch. 7-1.12. BATTERY INDICATOR INSTALLATION
2. Remove the compartment covers as described in 1. Position battery indicator on the bracket and
paragraph 5-2. secure with its mounting bracket and nuts.
3. Tag and disconnect main harness from buzzer. 2. Reconnect main harness to battery indicator.
4. Remove two screws and buzzer from the bracket.
3. Install the compartment covers as described in
7-1.8. BUZZER INSTALLATION paragraph 5-2.
4. Disengage the emergency brake switch and turn
1. Position buzzer on the bracket and secure with
on key switch.
the original hardware.
2. Reconnect main harness to buzzer. 7-1.13. LED INDICATOR REMOVAL
3. Install the compartment covers as described in 1. Engage the emergency brake switchand turn off
paragraph 5-2. key switch.
4. Disengage the emergency brake switch and turn 2. Remove the compartment covers as described in
on key switch. paragraph 5-2.

7-1.9. KEY SWITCH REMOVAL 3. Tag and disconnect main harness from LED indica-
tor.
1. Engage the emergency brake switch and turn off
4. Cut the glue holding the LED indicator in place
key switch.
and remove the indicator.
2. Remove the compartment covers as described in
paragraph 5-2.
3. Tag and disconnect main harness from key switch. 7-1.14. LED INDICATOR INSTALLATION
4. Remove mounting nut and key switch from the 1. Position LED indicator on the bracket and glue
bracket. it in place.
7-1.10. KEY SWITCH INSTALLATION 2. Reconnect main harness to LED indicator.
1. Position key switch on the bracket and 3. Install the compartment covers as described in
secure with its mounting nut. paragraph 5-2.
2. Reconnect main harness to key switch. 4. Disengage the emergency brake switch and turn
on key switch.
3. Install the compartment covers as described in
paragraph 5-2. 7-1.15. EMERGENCY DISCONNECT REMOVAL
4. Disengage the emergency brake switch and turn 1. Engage the emergency brake switch and turn off
on key switch. key switch.
7-1.11. BATTERY INDICATOR REMOVAL 2. Remove the compartment covers as described in
paragraph 5-2.
1. Engage the emergency brake switch and turn off
key switch. 3. Tag and disconnect cables from emergency brake
switch.
2. Remove the compartment covers as described in
paragraph 5-2. 4. Insert a tool through the shaft of emergency brake
switch and then unscrew the knob from the shaft.
3. Tag and disconnect main harness from battery
indicator. 5. Remove the two screws and remove the
emergency brake switch from the bracket.

7-4 T15-0416 - 08-09-2018

 Figure 7-3 Wiring Cables

7-1.16.

7-1.17. EMERGENCY DISCONNECT INSTALL.

1. Position emergency brake switch on the bracket
and secure with two screws.
2. Install the knob on the emergency disconnect.
3. Reconnect cables to emergency brake switch .
4. Install the compartment covers as described in
paragraph 5-2.
5. Disengage the emergency brake switch and turn
on key switch.

T15-0416 - 08-09-2018 7-5

 NOTES

7-6 T15-0416 - 08-09-2018

 SECTION 8
OPTIONAL EQUIPMENT

8-1. HOOK
Two hooks are available for option to the tow truck.

Figure 8-1 Hook Options

T15-0416 - 08-09-2018 8-1

 NOTES

8-2 T15-0416 - 08-09-2018

 SECTION 9
ILLUSTRATED PARTS BREAKDOWN

Following is an illustrated parts breakdown of assemblies and parts associated with the PDR Lift Truck.

T15-0416 - 08-09-2018 9-1

 R8180

Figure 9-1 Frame System

9-2 T15-0416 - 08-09-2018

 FRAME SYSTEM
Qty.
Pos. Part Number Description Notes
Reqd.
1 4310-110000-0E FRAME 1
2 4310-150001-00 FRONT COVER 1
3 4310-150002-00 BACK COVER 1
4 0000-000035-00 SCREW M5×20 4
5 0000-000206-00 LOCKWASHER Ø5 4
6 4310-140000-00 CASTER 2
7 0000-000277-00 BOLT M8×25 12
8 0000-000159-00 LOCKWASHER Ø8 19
9 0000-000550-00 NUT M8 8
10 4310-100003-00 FIXED BLOCK 2
11 0000-000063-00 LOCKWASHER Ø10 4
12 0000-000251-00 BOLT M10×25 4
13 4310-100002-00 BATTERY COVER 1
14 0000-000242-00 BOLT M8×16 2
15 0000-000390-00 FLATWASHER Ø5 4
16 4310-120000-0A BRACKET 1
17 4310-010000-00 CLIP HOOK 1
18 4310-100001-00 SPRING 1
19 0000-000109-00 SCREW M8×16 1
20 0000-000175-00 FLATWASHER Ø10 1
21 0000-001260-10 BUSHING 2512F 2
22 0000-000176-00 FLATWASHER Ø8 2
23 4310-150000-00 BRACKET 1
24 0000-000322-00 SCREW M8×25 4
25 4310-160000-00 BOLT 1

T15-0416 - 08-09-2018 9-3

 R8181

Figure 9-2 Hook Options

9-4 T15-0416 - 08-09-2018

 HOOK OPTIONS
Qty.
Pos. Part Number Description Notes
Reqd.
1 4310-010000-00 CLIP HOOK 1
2 0000-000277-00 BOLT M8×25 2
3 0000-000159-00 LOCKWASHER Ø8 4
4 4310-010000-A0 HOOK 2 1 Option
5 4310-000001-A0 PLATE 1
6 0000-001534-00 SCREW M 10×16 1
7 0000-000278-00 BOLT M8×30 4
8 0000-000550-00 NUT M8 8
9 4310-010000-A0-B HOOK 2 ASSEMBLY 1 Including item4,5,6

T15-0416 - 08-09-2018 9-5

 R8182

Figure 9-3 Driving System

9-6 T15-0416 - 08-09-2018

 DRIVING SYSTEM
Qty.
Pos. Part Number Description Notes
Reqd.
1 4310-210000-0A DRIVE UNIT 1
2 4310-220000-00 DRIVE WHEEL ASSEMBLY 2 Includes Pos. 3-11
3 4310-200003-00 AXLE 2
4 4310-200001-00 INNER HUB 2
5 4310-200004-00 OUTER TYRE 2
6 4310-200005-00 INNER TUBE 2
7 4310-200002-00 OUTER HUB 2
8 0000-000322-00 SCREW M 8×25 8
9 0000-000740-00 NUT M8 8
10 0000-000496-00 NUT M12×1.25 2
11 0000-000373-00 FLATWASHER Ø12 2
12 4310-211000-0A BRAKE 1

T15-0416 - 08-09-2018 9-7

 R8183

Figure 9-4 Operating Control System

9-8 T15-0416 - 08-09-2018

 OPERATING CONTROL SYSTEM
Qty.
Pos. Part Number Description Notes
Reqd.
Used up to serial number
1 4310-340000-00-B CONTROL HEAD ASSEMBLY 1
427102394 (With Wire)
Used from serial number
1a 1115-340000-00-90 CONTROL HEAD ASSEMBLY 1
427102395 (With Wire)
2 4310-310000-00 CONTROL HANDLE 1
3 4310-300002-00 TILT ADJUSTMENT KNOW 1
4 0000-000589-00 RETAINER RING Ø16 2
5 4310-300001-00 SHAFT 1
6 0000-000220-00 FLATWASHER Ø16 1
7 4310-530002-00 WIRE HARNESS 1

T15-0416 - 08-09-2018 9-9

 R8184

Figure 9-5 Control Head Assembly - Used up to serial number 427102394

9-10 T15-0416 - 08-09-2018

 CONTROL HEAD ASSEMBLY - USED UP TO SERIAL NUMBER 427102394
Qty.
Pos. Part Number Description Notes
Reqd.
Used up to serial number
1 4230-342000-00-B CAP ASSEMBLY 1
425131534 (With Wire)
Used between serial
1a 4310-342000-00-B CAP ASSEMBLY 1 number 425131535 and
427102395 (With Wire)
2 1120-340005-00 TRAVEL KNOB R 1
3 0000-000038-00 LOCKWASHER Ø3 2
4 0000-000037-00 SCREW M3×12 2
5 0000-000004-00 SCREW M5×12 2
6 0000-000206-00 LOCKWASHER Ø5 4
7 0000-000390-00 FLATWASHER Ø5 4
8 0000-000088-00 SCREW M4×8 2
9 0000-000122-00 LOCKWASHER Ø4 2
10 0000-000702-00 FLATWASHER Ø4 2
11 0000-000322-00 SCREW M8×25 2
12 0000-000159-00 LOCKWASHER Ø8 2
13 0000-000176-00 FLATWASHER Ø8 2
14 1120-340003-00 TRAVEL KNOB L 1
15 1120-343000-00-B REVERSING SWITCH ASSEMBLY 1 With Wire
16 0000-000004-00 SCREW M5×12 1
17 0000-000035-00 SCREW M5×20 4
18 1120-340002-00 COVER 1
19 1120-341000-00 GRIPE 1
20 1120-340001-00 POD 1
21 1220-520008-0C ACCELERATOR ASSEMBLY 1
22 0000-000010-00 SCREW M5×6 1

T15-0416 - 08-09-2018 9-11

 DU_0012

Figure 9-6 Control Head Assembly - Used from serial number 427102395

9-12 T15-0416 - 08-09-2018

 CONTROL HEAD ASSEMBLY - USED FROM SERIAL NUMBER 427102395
Qty.
Pos. Part Number Description Notes
Reqd.
1 1115-341000-00-90 CAP ASSEMBLY 1 With Wire
2 1115-340005-00 TRAVELLING KNOB R 1
3 0000-000038-00 LOCK WASHER Ø3 2
4 0000-000037-00 SCREW M3×12 2
5 1115-340006-00 SEAT 2
6 1115-340004-00 TRAVELLING KNOB L 1
7 1220-520008-0C ACCELERATOR 1
8 0000-000323-00 SCREW M5×16 1
9 0000-000390-00 FLAT WASHER Ø5 1
10 1115-340007-00 WIRE HARNESS COVER 1
11 1115-520004-10 REVERSING SWITCH WIRE 1
12 0000-000989-00 SCREW M2×12 2
13 1115-340003-00 COVER 1
14 1121-310004-00 SPRING 2
15 1115-340002-00 COVER 1
16 0000-000322-00 SCREW M8×25 4
17 0000-000159-00 LOCK WASHER Ø8 4
18 0000-000176-00 FLAT WASHER Ø8 4
19 1115-340001-00 WASHER 2
20 0000-000035-00 SCREW M5×20 4

T15-0416 - 08-09-2018 9-13

 R8185

Figure 9-7 Control Head Covers - Used up to Serial Number 425131534

9-14 T15-0416 - 08-09-2018

 CONTROL HEAD COVERS - USED UP TO SERIAL NUMBER 425131534
Qty.
Pos. Part Number Description Notes
Reqd.
1 1120-342001-00 UPPER COVER 1
2 1120-342203-00 LIFT BUTTON (R) 1
3 1120-342202-00 LOWERING BUTTON (R) 1
4 1120-342102-00 SPRING 8
5 1120-342201-00 BUTTON BRACKET (R) 1
6 1120-342105-00 PIN 6
7 1120-342104-00 LIFT BUTTON (L) 1
8 1120-342103-00 LOWERING BUTTON (L) 1
9 1120-342101-00 BUTTON BRACKET (L) 1
10 1120-342300-00 HORN BUTTON ASSEMBLY 1
11 1120-342300-00 SCREW ST3.5×9.5 4
12 0000-000490-00 LINE CLAMP 1
13 1120-342200-00 LIFT AND LOWER BOX ASSEMBLY (R) 1
14 1120-342100-00 LIFT AND LOWER BOX ASSEMBLY (L) 1
15 4230-520004-00 BUTTONS WIRE 1
16 1220-560002-00 SWITCH 1
17 1120-342002-00 HORN BUTTON 1
18 1120-342005-00 PIN 2
19 1120-342003-00 SPRING 2
20 1120-342004-00 BUTTON BRACKET 1

T15-0416 - 08-09-2018 9-15

 R8185

Figure 9-8 Control Head Covers - Used from Serial Numbers 425131535

9-16 T15-0416 - 08-09-2018

 CONTROL HEAD COVERS - USED FROM SERIAL NUMBERS 425131535
Qty.
Pos. Part Number Description Notes
Reqd.
Used between serial
1 1120-342001-00 UPPER COVER 1 number 425131535-
427102394
Used from serial number
1a 1115-341001-00 UPPER COVER 1
427102395
2 4310-340002-00 SEALED COVER (R) 1
3 4310-340001-00 SEALED COVER (L) 1
4 1120-342300-00 HORN BUTTON ASSEMBLY 1
5 0000-000039-00 SCREW ST3.5 x 9.5 4
6 1120-342002-00 HORN BUTTON 1
7 1120-342005-00 PIN 2
8 1120-342003-00 SPRING 2
9 1120-342004-00 BUTTON BRACKET 1
10 1220-560002-00 SWITCH 1
11 0000-000490-00 LINE CLAMP 1
12 4230-520004-00 BUTTONS WIRE 1

T15-0416 - 08-09-2018 9-17

 R8186

Figure 9-9 Emergency Reverse Switch Assembly - Used up to serial number 427102394

9-18 T15-0416 - 08-09-2018

 EMERGENCY REVERSE SWITCH ASSEMBLY - USED UP TO SERIAL NUMBER 427102394
Qty.
Pos. Part Number Description Notes
Reqd.
1 1120-343002-00 COVER 1
2 1120-343003-00 SPRING 2
3 1120-342005-00 PIN 2
4 1120-343001-0A BRACKET 1
5 1120-343004-00 PIN 1
6 1220-520005-0C REVERSING SWITCH WIRE 1
7 1220-560002-00 INCHING SWITCH II 1

T15-0416 - 08-09-2018 9-19

 R8187

Figure 9-10 Electrical System

9-20 T15-0416 - 08-09-2018

 ELECTRICAL SYSTEM
Qty.
Pos. Part Number Description Notes
Reqd.
1 1115-510008-00 EMERGENCY STOP SWITCH 1
2 0000-000616-00 SCREW M5×10 2
3 1115-510009-00 LAMP HOLDER 1
4 1115-520013-00 LED WIRE HARNESS 1
5 1115-520019-0A 2-WAY KEY SWITCH ASSEMBLY 1
6 1115-500016-00 2 WAY SWITCH KEY 2
7 1115-510006-2B-02 METER 803 1
8 1115-520005-20 METER 803 WIRE HARNESS 1
9 1120-540001-00-B FUSE STAND 1
10 1115-510003-00 FUSE 100A 1
11 0000-000126-00 SCREW M 6×16 2
12 0000-000196-00 NUT M8 2
13 0000-000176-00 FLATWASHER Ø8 4
14 1115-520015-00 BUZZER ASSEMBLY 1
15 0000-000666-00 SCREW M3×8 2
16 0000-001134-00 O-RING Ø2.0×1.8 2
17 4310-510001-00 BRACKET 1
18 0000-000323-00 SCREW M5×16 8
19 0000-000206-00 LOCKWASHER Ø5 8
20 1115-510004-00-H0 CONTROLLER 1
21 0000-000664-00 SCREW M4×40 2
22 0000-000122-00 LOCKWASHER Ø4 2
23 4310-500001-00 BATTERY 2 50AH
24 2112-410005-00 RUBBER CUSHION 6
Used up to serial number
25 4310-530007-00 CHARGER ,5A 1
425210696
Used from serial number
25a 4310-530008-00 CHARGER ,8A 1
425210697
26 1115-500009-00 CHARGER HOOP 2
27 0000-000128-00 FLATWASHER Ø5 8
28 4310-540000-10 CHARGER CABLE WINDING ROLL 1
29 1115-120002-00 CHARGER CAP 1
30 1115-510008-10 SWITCH BUTTON 1
31 0000-000004-00 SCREW M5×12 4
32 4310-500002-00 PLATE 1

T15-0416 - 08-09-2018 9-21

 R8188

Figure 9-11 Wire Harness Assembly

9-22 T15-0416 - 08-09-2018

 WIRE HARNESS ASSEMBLY
Qty.
Pos. Part Number Description Notes
Reqd.
1 4310-530001-0A MASTER WIRE HARNESS 1
2 1120-500010-00 FUSE 10A 1

T15-0416 - 08-09-2018 9-23

 R8189

Figure 9-12 Cable Assembly

9-24 T15-0416 - 08-09-2018

 CABLE ASSEMBLY
Qty.
Pos. Part Number Description Notes
Reqd.
1 4310-520001-00 FUSE-CONTROLLER CABLE 1
2 4310-520002-00 B - CABLE 1
3 4310-520003-00 EMERGENCY STOP SWITCH CABLE 1
4 4310-520004-00 BATTERY CONNECTOR CABLE 1
5 4310-520005-00 B+ CABLE 1

T15-0416 - 08-09-2018 9-25

Big Lift LLC