Blue Giant EPS-22 Owner's Manual

Blue Giant EPS-22 Owner's Manual

Powered straddle truck
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OWNER'S MANUAL
EPS-22 POWERED STRADDLE TRUCK
WARNING
Do not operate or service this product unless you have
read and fully understand the entire contents of this
manual. Failure to do so may result in property damage,
bodily injury or death.
ISSUE DATE:APRIL 3, 2014 REV.0 (PART # 038-925E)

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Summary of Contents for Blue Giant EPS-22

  • Page 1 OWNER’S MANUAL EPS-22 POWERED STRADDLE TRUCK WARNING Do not operate or service this product unless you have read and fully understand the entire contents of this manual. Failure to do so may result in property damage, bodily injury or death.
  • Page 2 WARNING Do not operate this truck unless you have been autho- Do not overload truck. Check nameplate for capacity rized and trained to do so, and have read all warnings and load center information. and instructions in Operator’s Manual and on this When using forks, space forks as far apart as load will truck.
  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section Page Section Page 1 DESCRIPTION ............1-1 5-1.7. HORN SWITCH REPLACEMENT....5-4 1-1. INTRODUCTION..........1-1 5-1.8. LIFT AND LOWER SWITCH 1-2. GENERAL DESCRIPTION......1-1 REPLACEMENT.......... 5-6 1-3. SAFETY FEATURES........1-1 5-2. STEERING ARM .......... 5-6 5-2.1. RETURN SPRING REPLACEMENT.
  • Page 4 TABLE OF CONTENTS Section Page Section Page 10-1.5. CHARGER REMOVAL......10-1 10-1.18. EMERGENCY DISCONNECT 10-1.6. CHARGER INSTALLATION....... 10-1 INSTALLATION.......... 10-5 10-1.7. COOLING FAN REMOVAL (MONO)..10-4 10-1.19. LIFT LIMIT SWITCH REMOVAL....10-5 10-1.8. COOLING FAN INSTALLATION (MONO). 10-4 10-1.20.
  • Page 5: Description

    SECTION 1 DESCRIPTION 1-1. INTRODUCTION. This publication describes the 24 volt transistor S22 lift truck distributed by Big Lift LLC. Included are MODEL NO. SERIAL NO. operating instructions, planned maintenance instruc- MAX CAP LB/ MAX CAP LB/ LOAD CTR IN/ LOAD CTR IN/ LIFT HGT IN/ tions, lubrication procedures, corrective maintenance...
  • Page 6 R6841 Figure 1-2 S22 Lift Truck ITEM COMPONENT ITEM COMPONENT Battery Control handle. Chassis Key switch Caster LED indicator Cover Mast cover Drive wheel Lift cylinder Cover Battery indicator Hydraulic reservoir Battery charger connector Hydraulic pump Emergency brake switch Forks BG-S22-0812...
  • Page 7: Operation

    SECTION 2 OPERATION 2-1. GENERAL. • Be certain that the lifting mechanism is operating smoothly throughout its entire height, both empty This section gives detailed operating instructions for and loaded. the S22 lift truck. The instructions are divided into the various phases of operations, such as operating lift, •...
  • Page 8: Before Operation

    • When stacking pallets in racks and it is necessary to Figure 2-2 shows a sample format for an Operator move the load in a raised position, use caution. Checklist, which can be modified as necessary to fit Operate truck smoothly. your operation.
  • Page 9: Sample Of Operator Check List

    Electric Truck Daily Operator Check-Off List Big Joe Manufacturing Company Date Operator Truck No. Model No. Dept. Shift Hour Meter Reading Drive Hoist Check O.K. ( ) Need Maintenance Tires Load Wheels Horn Lift Lower Control Attachment Operation Forward & Reverse Controls Steering Brakes Hydraulic Leaks, Cylinders,...
  • Page 10: General Control Operation

    2-4. GENERAL CONTROL OPERATION. Lower the steering arm to a comfortable position above horizontal to disengage the brake and to The speed control (See Figure 2-3) located on each energize the electrical circuits. If the truck is not side of the control head provides fingertip control for moved, the electrical circuits will time out and will driving the truck.
  • Page 11: Belly-Button Switch

    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 replace- ment.
  • Page 12 NOTES BG-S22-0812...
  • Page 13: Planned Maintenance

    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.
  • Page 14: 3-3.2. Safety Rules

    Although a leakage voltage reading of zero volts may Battery terminals should be checked and cleaned not be possible, a cleaner battery will have more of corrosion regularly. Good battery terminal con- usable charge for truck operation and not affect opera- tact is essential not only for operation, but also for tion of electronic devices on the unit.
  • Page 15: Charging Batteries

    3-4. CHARGING BATTERIES Charging requirements will vary depending on depth of discharge and temperature. Follow safety rules when placing a battery on charge. Proceed as follows: Park truck at charging station with carriage low- ered and turn the key switch off. Check the condition of the AC cord and battery cables.
  • Page 16: Lubrication

    Tag and disconnect the three cables from the bat- teries and replace the batteries. Install in the reverse order of removal. 3-6. LUBRICATION. Refer to Table 3-2 for the recommended types of grease and oil. Table 3-3 in conjunction with Figure 3-4 identifies the items requiring lubrication.
  • Page 17: Lubrication Diagram

    R6871 Figure 3-4 Lubrication Diagram Table 3-3 Lubrication Chart FIG 3-2 LOCATION METHOD OF TYPE APPLICATION INDEX APPLICATION (Table 3-3) LUBRICANT Inner & Outer Mast Brush No. 2 Full length of channel where rollers operate. Lift Chain Brush or Spray No.
  • Page 18 NOTES BG-S22-0812...
  • Page 19: Troubleshooting

    SECTION 4 TROUBLESHOOTING 4-1. GENERAL Operate: Truck Does Not Operate Forward or Reverse: Trouble With Braking: Trouble With Lifting Or Table 4-1 as a guide to determine possible Lowering, and Miscellaneous malfunctions. causes of trouble. The table is divided into five main categories: Truck and Hydraulic System Will Not Table 4-1 Troubleshooting Chart MALFUNCTION...
  • Page 20 Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH BRAKING Truck does not slow with brake, or a. Defective deadman switch (16, Check deadman switch for brake does not engage. Figure 12-1). continuity. If none found when the control arm is in the brake position, replace switch.
  • Page 21: Steering Arm

    Table 4-1 Troubleshooting Chart - Continued MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION TROUBLE WITH LIFTING OR LOWERING - Continued Forks do not lift, motor runs. Defect in hydraulic system. Check the oil level in the reservoir and the oil lines to the lift cylin- der, and repair as required.
  • Page 22: Controller Troubleshooting

    4-2. CONTROLLER TROUBLESHOOTING Disconnect the battery charger and connect the programmer to the 4-pin connector (Figure 4-1) 4-2.1. Fault Detection. on the controller. The controller provides diagnostics information to assist technicians in troubleshooting drive system problems. When a fault is detected, the appropriate fault code is signaled via the panel mounted LED.
  • Page 23 Put the controller into the diagnostic mode by Put the controller into the test mode by using the pressing the "Menu Navigation Key" (1, Figure 4- Navigation key (1) to select the "Monitor" menu. 2). Using the Navigation key, select the Faults Select the Monitor mode by pressing the "Right"...
  • Page 24: Diagnostic History

    4-2.5. Diagnostic History Disengage the emergency stop switch (31, Figure 12-22 or 28, Figure 12-23) and turn on key switch The handheld programmer can be used to access the Figure 12-22 or 3, Figure 12-23). controller's diagnostic history file. When the program- Leave the key switch on and remove the in-line mer is connected to the unit, the error log file is auto- fuse wire.
  • Page 25 Table 4-2 Programmable Parameters Parameter Factory Setting Description DRIVE MENU Accel Max Speed Sets the rate (in seconds) at which the speed command increases when throttle is applied with the speed limit pot is in its maximum speed position, and the vehicle is traveling forward.
  • Page 26 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description DRIVE MENU - Continued Rev Decel Low Sets the rate (in seconds) that is used to slow down the vehicle Speed when it is traveling in reverse at low speed and throttle is reduced.
  • Page 27 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description SPEED MENU M1/M2 Max Speed 100% During forward operation, defines the requested speed at full throttle when the speed limit pot is in its maximum speed position. Note: Allowable range is restricted by the M1/M2 Min Speed setting.
  • Page 28 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description THROTTLE MENU Type The 1212 controller can accept inputs from both 5kΩ, 3-wire pot throttles and voltage throttles. Set the throttle type param- eter to match the throttle used in your application. 5kΩ, 3-wire pot throttles 0 = wigwag 1 = inverted wigwag...
  • Page 29 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description THROTTLE MENU - Continued Throttle Map The throttle map parameter adjusts the static throttle map. The parameter setting corresponds to the throttle command at half throttle. A setting of 50% provides linear response. Values below 50% reduce the throttle command at low throttle positions, provid- ing enhanced slow speed maneuverability.
  • Page 30 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description INHIBIT MENU Type The flexible speed input at J1 Pin 6 can be used to limit or to inhibit speed under certain conditions. For example, a switch could be installed under the seat so that if the operator drives the scooter while they are standing the max speed will be lim- ited.
  • Page 31 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description HORN MENU - Continued Beep Constant Sets the reverse beep to be a constant tone (when pro- grammed On) or a 1Hz pulse (when programmed Off). MOTOR MENU System Resistance Sets the system resistance (motor + brushes + wiring + con- nections) used for load compensation and speed estimation.
  • Page 32 Table 4-2 Programmable Parameters - Continued Parameter Factory Setting Description BDI MENU - Continued Start Charger 28.1 Voltage above which the battery is considered to start charg- Voltage ing. Note: Allowable range is restricted by the Full Voltage and Full Charge Voltage settings.
  • Page 33: Diagnostics And Troubleshooting

    4-2.8. Diagnostics and Troubleshooting. For suggestions about possible causes of the various faults, refer to Table 4-4 Troubleshooting Chart. The motor controller provides diagnostics information to assist in troubleshooting drive system problems. 4-2.9. Programmer Diagnostics The diagnostics information can be obtained in two With a programmer, diagnostics and troubleshooting is ways: more direct than with the LED alone.
  • Page 34 Table 4-4 Troubleshooting Chart PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE CODE LCD DISPLAY Battery Disconnect Battery disconnected 1. Battery not connected. Fault 2. Poor connection to battery terminals. Battery OFF Fault Brake OFF Fault 1. Electromagnetic brake driver open. 2. Electromagnetic brake coil shorted. Brake ON Fault Brake ON fault 1.
  • Page 35 Table 4-4 Programmable Parameters - Continued PROGRAMMER POSSIBLE CAUSE FAULT CLEARANCE CODE LCD DISPLAY Throttle Fault PotLow and /or PotWiper out of range 1. Throttle input wire open or shorted. 2. Throttle pot defective. 3. Wrong throttle type selected. Undervoltage Fault Battery voltage too low 1.
  • Page 36 NOTES 4-18...
  • Page 37: Steering Arm, Control Head And Compartment

    SECTION 5 STEERING ARM, CONTROL HEAD AND COMPARTMENT 5-1. CONTROL HEAD Remove four screws (17, Figure 5-1), lift up cap assembly (21) and disconnect harness (23) from 5-1.1. Cap Assembly Removal. harness (15, Figure 5-2). Engage the emergency stop switch (31, Figure 12-22 or 28,...
  • Page 38: 5-1.2. Cap Assembly Installation

    5-1.2. Cap Assembly Installation. Position cap assembly (21, Figure 5-1) on control head and secure with four screws (17). Hold cap assembly (21, Figure 5-1) in place and Disengage the emergency stop switch (31, Figure connect harness (23) to harness (15, Figure 5-2).
  • Page 39: 5-1.3. Control Head Removal

    5-1.3. Control Head Removal Position new potentiometer (15) in bracket (20) and secure with screw (16), lock washer (6) and Remove the cap assembly as described in para- flat washer (7). graph 5-1.1. Install screw (1), lock washer (6) and flat washer Disconnect harness (15, Figure 5-2) from potenti-...
  • Page 40: Horn Switch Replacement

    R6810 Figure 5-3 Emergency Reverse Switch Assembly 5-1.7. Horn Switch Replacement. Unsolder harness from defective switch and con- nect it to the new switch. Remove the cap assembly as described in para- Position the new switch in bracket (14) and graph 5-1.1.
  • Page 41: Cap Assembly

    R6847 Figure 5-4 Cap Assembly...
  • Page 42: Lift And Lower Switch Replacement

    5-1.8. Lift and Lower Switch Replacement. Disengage the emergency stop switch (31, Figure 12-22 or 28, Figure 12-23) and turn on key switch Remove the cap assembly as described in para- Figure 12-22 or 3, Figure 12-23). graph 5-1.1. Remove switch assembly (1 or 1A, Figure 5-4) 5-2.2.
  • Page 43: Mono Mast Cover

    5-4. MONO MAST COVER 5-4.2. Installation. Install cover (3, Figure 12-6) and secure with six 5-4.1. Removal. screws (1) and six washers (2). Engage the emergency stop switch (31, Figure Disengage the emergency stop switch (31, Figure 12-22 or 28, Figure 12-23) and turn off key switch 12-22...
  • Page 44 NOTES...
  • Page 45: Brake Servicing

    SECTION 6 BRAKE SERVICING 6-1. BRAKES. Disconnect electric brake from harness (1, Figure 12-24 Figure 12-25). The brake system consists of a drive motor mounted Remove the two mounting screws (2, Figure 6-1) brake. This brake is spring applied and electrically and the brake.
  • Page 46: Transmission, Motor, Brake Assembly

    R6848 Figure 6-1 Transmission, Motor, Brake Assembly...
  • Page 47: Transmission, Drive Wheel, Load Wheel

    SECTION 7 TRANSMISSION, DRIVE WHEEL, LOAD WHEEL 7-1. Drive Wheel. Remove the compartment covers as described in paragraph 5-3. Remove the transmission as described in para- Remove the steering arm as described in para- graph 7-2. graph 5-2. Remove the two mounting screws (2, Figure 7-1) Raise the truck off the ground to provide clear-...
  • Page 48: Transmission, Motor, Brake Mounting

    R6848 Figure 7-1 Transmission, Motor, Brake Mounting...
  • Page 49: Load Wheel

    7-3. Load Wheel. 7-3.2. Repair Remove bearings (8, Figure 12-8 Figure 12-9) 7-3.1. Removal from wheels (9). Raise forks. Inspect bearings (8) and replace if necessary. Engage the emergency stop switch (31, Figure Reassemble bearings (8) in wheels (9). 12-22 or 28, Figure 12-23) and turn off key switch...
  • Page 50 NOTES...
  • Page 51: Elevation System Servicing

    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. 8-2.1. Mono Fully lower the lift carriage. Engage the emergency stop switch (31, Figure 12-22 or 28,...
  • Page 52: Telescopic

    8-2.2. Telescopic Fully lower the lift carriage. Engage the emergency stop switch (31, Figure 12-22 or 28, Figure 12-23) and turn off key switch Figure 12-22 or 3, Figure 12-23). WARNING: Before attempting any adjustment, make certain power is disconnected. Loosen jam nut (3, Figure 8-2), located the above...
  • Page 53: Lift Chain Replacement

    8-4. LIFT CHAIN REPLACEMENT. 8-4.2. Telescopic With the lift truck wheels securely blocked, raise 8-4.1. Mono the forks approximately three feet from floor and With the lift truck wheels securely blocked, raise position blocks or strong supports under the inner the forks approximately three feet from floor and mast.
  • Page 54 NOTES...
  • Page 55: Hydraulic System Servicing

    SECTION 9 HYDRAULIC SYSTEM SERVICING 9-1. LINES AND FITTINGS Remove the compartment covers as described in paragraph 5-3. WARNING: When forks are raised, pressure exists in Remove the mono mast cover as described in the hydraulic system lines and fittings. paragraph 5-3.
  • Page 56: Hydraulic Pump, Motor, And Reservoir Assy

    Check level of hydraulic oil. If required, add 11. Install the mono mast cover as described in para- hydraulic oil to bring to proper level. Use hydraulic graph 5-3. oil listed in Table 3-2. 9-2. HYDRAULIC PUMP, MOTOR, AND RESER- Disengage the emergency stop switch (31, Figure VOIR ASSY...
  • Page 57: Removal

    9-2.1. Removal Check level of hydraulic oil. If required, add hydraulic oil to bring to proper level. Use hydraulic Lower forks fully. oil listed in Table 3-2. Engage the emergency stop switch (31, Figure Install the compartment covers as described in 12-22 or 28, Figure...
  • Page 58: Elevation System (Mono)

    R6854 Figure 9-3 Elevation System (Mono)
  • Page 59: Repair

    9-3.2. Repair Disengage the emergency stop switch (31, Figure 12-22 or 28, Figure 12-23) and turn on key switch CAUTION: To prevent damage, use proper pipe Figure 12-22 or 3, Figure 12-23). clamp vise. The cylinder will be distorted 10. Operate the lift and lower buttons to refill the if the vise is tightened too much.
  • Page 60: Lift Cylinder (Telescopic)

    9-4. Lift Cylinder (Telescopic) Remove piston (2) and O-ring (3) from rod (1). Remove guide ring (10) and seal (11) from piston 9-4.1. Removal (2). With the lift truck wheels securely blocked, raise Coat all parts with hydraulic oil (Table 3-2).
  • Page 61: Elevation System (Telescopic)

    R6855 Figure 9-6 Elevation System (Telescopic)
  • Page 62: Installation

    9-4.3. Installation Disengage the emergency stop switch (31, Figure 12-22 or 28, Figure 12-23) and turn on key switch Position the cylinder in the mast. Figure 12-22 or 3, Figure 12-23). Install screw (32, Figure 9-6), lock washer (11) Operate the lift and lower buttons to refill the and flat washer (12) to secure the bottom of the cylinder and lines with hydraulic oil.
  • Page 63: Electrical Components

    SECTION 10 ELECTRICAL COMPONENTS 10-1.ELECTRICAL CONTROL PANEL Tag and disconnect remaining leads from the controller. Refer to Figure 12-26 Figure 12-27). 10-1.1.Maintenance Remove mounting screws, lock washers and remove controller (13, Figure 10-1 or 9, Figure 10- NOTE: Erratic operation of the truck may be caused 2) and heat sink.
  • Page 64 R6865 Figure 10-1 Electrical System (Mono) 10-2 BG-S22-0812...
  • Page 65 R6866 Figure 10-2 Electrical System (Telescopic) BG-S22-0812 10-3...
  • Page 66: 10-1.7.Cooling Fan Removal (Mono)

    Reconnect remaining two charger leads. Disengage the emergency stop switch (31, Figure 10-1 or 28, Figure 10-2) and turn on key switch (4, Install compartment covers as described in para- Figure 10-1 or 3, Figure 10-2). graph 5-3. Disengage the emergency stop switch (31, Figure 10-1.11.Key Switch Removal.
  • Page 67: 10-1.15.Led Indicator Removal

    Install upper compartment covers as described in Install the knob on the emergency disconnect. paragraph 5-3. Reconnect cables (3 and 4, Figure 12-26 Fig- Disengage the emergency stop switch (31, Figure 12-27) to emergency disconnect (31, Figure 10-1 or 28, Figure 10-2) and turn on key switch (4, 10-1...
  • Page 68: Deadman Switch

    10-4.DEADMAN SWITCH Remove two screws (7) and switch (16) from bracket (8). Engage the emergency stop switch (31, Figure Position the new switch (16) on bracket (8) and 10-1 or 28, Figure 10-2) and turn off key switch (4, secure with the two screws (7). Figure 10-1 or 3, Figure...
  • Page 69: Optional Equipment

    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. BG-S22-0812 11-1...
  • Page 70 NOTES 11-2 BG-S22-0812...
  • Page 71: Illustrated Parts Breakdown

    SECTION 12 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the S22 Lift Truck. BG-S22-0812 12-1...
  • Page 72: Steering System

    R6846 Figure 12-1 Steering System 12-2 BG-S22-0812...
  • Page 73 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — CONTROL HEAD 0000-000322-00 SCREW, M8 x 25 (FIGURE 12-2) 0000-000030-00 SCREW, M10 x 16 2108-300002-00 SHAFT 0000-000386-00 SCREW, M6 x 20 1120-320000-00 GAS SPRING 0000-000056-00 WASHER, LOCK, M6 1115-310000-00 STEERING ARM 2108-300001-00 BRACKET...
  • Page 74: Control Head

    R6808 Figure 12-2 Control Head 12-4 BG-S22-0812...
  • Page 75 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 0000-000004-00 • SCREW, M5 X 12 1120-340000-00 CONTROL HEAD 0000-000035-00 • SCREW, M5 X 20 0000-000010-00 • SCREW, M5 X 6 1120-340002-00 • COVER 1120-340005-00 • CONTROL KNOB 1120-341000-00 •...
  • Page 76: Cap Assembly

    R6847 Figure 12-3 Cap Assembly 12-6 BG-S22-0812...
  • Page 77 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 1120-342103-00 • • BUTTON, LOWERING, 1120-342000-00 CAP ASSEMBLY LEFT, TWO SPEED 1120-342200-00 • LIFT/LOWERING SWITCH 1120-342101-00 • • BUTTON BRACKET, ASSY, RIGHT LEFT 1120-342100-00 • LIFT/LOWERING SWITCH 1120-342002-00 • HORN BUTTON ASSY, LEFT 0000-000039-00 •...
  • Page 78 R6810 Figure 12-4 Emergency Reverse Switch Assembly INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 1120-342005-00 • PIN 1120-343000-00 EMERGENCY REVERSE SWITCH ASSY 1120-343001-0A • BRACKET 1120-343002-00 • EMERGENCY REVERSE 1120-343004-00 • PIN BUTTON 1120-343003-00 • SPRING 12-8 BG-S22-0812...
  • Page 79 NOTES BG-S22-0812 12-9...
  • Page 80 R6848 Figure 12-5 Transmission, Motor, Brake Assembly 12-10 BG-S22-0812...
  • Page 81 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000680-00 BEARING, 16003Z 1115-520012-00 BRAKE — GEAR SET (REPLACE 0000-000121-00 • SCREW, M4 X 35 BOTH) 1115-240001-00 • FRICTION PLATE 19A 1115-200002-00 GEAR, LOOP 0000-000665-00 • SCREW, M4 X 45 19B 1115-200003-00 GEAR 0000-000668-00...
  • Page 82: Compartment, Mono

    R6849 Figure 12-6 Compartment, Mono 12-12 BG-S22-0812...
  • Page 83 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000179-00 SCREW, M6 X 10 2108-100006-00 SCREW, M6 X 10 2108-100004-00 ROTATION COVER 2214-150002-00 WASHER, M6 2108-100005-00 BRACKET 2108-100001-00-01 COVER 2108-100003-00 COVER 2108-100002-00 COVER BG-S22-0812 12-13...
  • Page 84: Compartment, Telescopic

    R6850 Figure 12-7 Compartment, Telescopic 12-14 BG-S22-0812...
  • Page 85 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2108-100004-00 ROTATION COVER 2108-100006-00 SCREW, M6 X 10 2108-100005-00 BRACKET 2214-150002-00 WASHER, M6 2108-100003-00 COVER 2108-100002-00 COVER 0000-000179-00 SCREW, M6 X 10 BG-S22-0812 12-15...
  • Page 86: Adjustable Straddle, Mono

    R6851 Figure 12-8 Adjustable Straddle, Mono 12-16 BG-S22-0812...
  • Page 87 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 0000-000424-00 BEARING, 6205-2Z CASTER ASSEMBLY (FIGURE 12-10) 2125-101001-00 LOAD WHEEL 0000-000322-00 SCREW, M8 X 25 2125-101002-00 SHAFT 0000-000159-00 WASHER, LOCK, M8 2108-130000-10 STRADDLE, RIGHT 0000-000194-00 WASHER, FLAT, M8 2108-120000-10 STRADDLE, LEFT 2130-110000-00 FRAME...
  • Page 88: Adjustable Straddle, Telescopic

    R6852 Figure 12-9 Adjustable Straddle, Telescopic 12-18 BG-S22-0812...
  • Page 89 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 0000-000424-00 BEARING, 6205-2Z CASTER ASSEMBLY (FIGURE 12-10) 2125-101001-00 LOAD WHEEL 0000-000322-00 SCREW, M8 X 25 2125-101002-00 SHAFT 0000-000159-00 WASHER, LOCK, M8 2108-130000-10 STRADDLE, RIGHT 0000-000194-00 WASHER, FLAT, M8 2108-120000-10 STRADDLE, LEFT 2108-110000-60 FRAME...
  • Page 90: Caster

    R6853 Figure 12-10 Caster 12-20 BG-S22-0812...
  • Page 91 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 0000-000242-00 • SCREW, M8 X 16 2108-140000-10 CASTER ASSEMBLY 0000-000159-00 • WASHER, LOCK, M8 0000-000093-00 • NUT, M27 X 1.5 2140-142000-00 • HINGE PIN 0000-000094-00 • WASHER 2140-145000-00 • SHAFT 1220-140001-00 •...
  • Page 92: Elevation System (Mono)

    R6854 Figure 12-11 Elevation System (Mono) 12-22 BG-S22-0812...
  • Page 93 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000373-00 WASHER, FLAT, M12 0000-000756-00 RETAINER RIN 0000-000321-00 SCREW, M8 X 20 2108-600001-00 SHAFT 2108-600004-00 CLIP, CYLINDER 2108-600003-00 WASHER — LIFT CYLINDER 2108-600002-00 CHAIN SHEAVES (FIGURE 12-20) 2108-620000-00 RAM HEAD 0000-000159-00 WASHER, LOCK, M8 0000-000374-00...
  • Page 94: Elevation System (Telescopic)

    R6855 Figure 12-12 Elevation System (Telescopic) 12-24 BG-S22-0812...
  • Page 95 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2108-600006-60 • COLUMN 0000-000761-00 SCREW, M5 X 6 0000-000777-00 • STEEL BALL 2108-600002-00 BOLT 2108-600007-60 • ROLLER 0000-000757-00 NUT, M20 X 1.5 0000-000420-00 • BEARING, 6206 2108-600003-60 SPRING 0000-000434-00 • RETAINING RING 2108-600004-60 POSITIONING ROD 0000-000762-00...
  • Page 96: Lift Carriage (Mono)

    R6856 Figure 12-13 Lift Carriage (Mono) 12-26 BG-S22-0812...
  • Page 97 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2125-612002-00 • BRACKET 2125-630001-00 FORK 2125-612001-00 • ROLLER 2125-630001-10 LOCK 2125-612005-00 • DUST SEAL 0000-000008-00 SCREW, M10 X 20 0000-000183-00 • RETAINING RING, M35 0000-000063-00 WASHER, LOCK, M10 2125-631104-00 • SCREW 2125-631100-00 ROLLER ASSEMBLY 2108-631000-10...
  • Page 98: Lift Carriage (Telescopic)

    R6857 Figure 12-14 Lift Carriage (Telescopic) 12-28 BG-S22-0812...
  • Page 99 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 2108-600007-60 • ROLLER 0000-000284-00 BOLT, M12 X30 0000-000420-00 • BEARING, 6206 0000-000060-00 WASHER, LOCK, M12 0000-000434-00 • RETAINING RING 0000-000373-00 WASHER, FLAT, M12 0000-000762-00 • SNAP RING 2125-632000-00 BACK SUPPORT 2108-631000-60 CARRIAGE 2108-632000-60...
  • Page 100 INDEX PART PART NAME REQD. 2108-640000-00-01 CHAIN (63 LINKS) 2108-640001-00 ADJUSTING SCREW 0000-000237-00 NUT, M16 X 1.5 2108-640002-00 0000-000188-00 PIN, COTTER R6858 Figure 12-15 Chain Assembly (Mono) 12-30 BG-S22-0812...
  • Page 101 INDEX PART PART NAME REQD. 2125-640001-60-01 CHAIN (96 IN LIFT) (131 LINKS) 2125-640001-60-02 CHAIN (116 IN LIFT) (143 LINKS) 2108-640002-60 ADJUSTING SCREW 0000-000237-00 NUT, M16 X 1.5 0000-000220-00 WASHER, M16 0000-000188-00 PIN, COTTER 0000-000779-00 R6859 Figure 12-16 Chain Assembly (Telescopic) BG-S22-0812 12-31...
  • Page 102: Hydraulic System (Mono)

    R6860 Figure 12-17 Hydraulic System (Mono) INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 0000-000472-00 CLAMP PUMP & MOTOR ASSY (FIGURE 12-19) 2108-400002-00-01 HOSE 0000-000109-00 SCREW, M8 X 16 0000-000069-00 SEAL 0000-000159-00 WASHER, LOCK, M8 2701-161600-00 CONNECTOR 0000-000176-00 WASHER, FLAT, M8 2108-400001-00...
  • Page 103: Hydraulic System (Telescopic)

    R6861 Figure 12-18 Hydraulic System (Telescopic) INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 0000-000472-00 CLAMP PUMP & MOTOR ASSY (FIGURE 12-19) 2108-400002-00-03 HOSE (96 IN LIFT) 0000-000109-00 SCREW, M8 X 16 2108-400002-00-04 HOSE (116 IN LIFT) 0000-000159-00 WASHER, LOCK, M8 0000-000634-00...
  • Page 104: Pump & Motor Assy

    R6862 Figure 12-19 Pump & Motor Assy 12-34 BG-S22-0812...
  • Page 105 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. — 2108-422009-00 • PLUG, PLASTIC 2108-422000-00 PUMP & MOTOR ASSY 2108-422010-00 • SOLENOID VALVE 2108-422001-00 • MOTOR 2108-422011-00 • CHECK VALVE 2108-422002-00 • SOLENOID 2108-422012-00 • CONNECTOR 2108-422003-00 • RELIEF VALVE 0000-000763-00 •...
  • Page 106 INDEX PART PART NAME REQD. — 2110-410000-00-01 LIFT CYLINDER — • PISTON ROD 2125-410002-00 • PISTON 2125-410003-00 • O-RING 2125-410006-00 • BUSHING 0000-000711-00 • BEARING, 3530 — • CYLINDER TUBE 2125-410004-0A • GLAND NUT 0000-000084-00 • WIPER RING 0000-000370-00 • O-RING 2125-410005-00 •...
  • Page 107 INDEX PART PART NAME REQD. — 2108-410000-60-01 LIFT CYLINDER (96 IN LIFT) — 2108-410000-60-02 LIFT CYLINDER (116 IN LIFT) — • PISTON ROD 2125-410002-00 • PISTON 2125-410003-00 • O-RING 2125-410006-00 • BUSHING 0000-000711-00 • bearing, 3530 — • CYLINDER TUBE 2125-410004-0A •...
  • Page 108 R6865 Figure 12-22 Electrical System (Mono) 12-38 BG-S22-0812...
  • Page 109 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000176-00 WASHER, FLAT, M8 0000-000121-00 SCREW, M4 X 35 0000-000378-00 SCREW, M4 X 16 1115-500007-00 GUARD 1120-500005-00 TERMINAL 1115-520007-00 0000-000010-00 SCREW, M5 X 6 1115-520003-00 KEY SWITCH 2108-520006-00 SWITCH, LIMIT 1120-500016-00 •...
  • Page 110: Electrical System (Telescopic)

    R6866 Figure 12-23 Electrical System (Telescopic) 12-40 BG-S22-0812...
  • Page 111 INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 0000-000196-00 NUT, M8 0000-000666-00 SCREW, M3 X 8 0000-000194-00 WASHER, FLAT, M8 1115-520015-00 BUZZER 1115-510003-00 FUSE, 100A 1115-520003-00 KEY SWITCH 0000-000126-00 SCREW, M6 X 16 1120-500016-00 • KEY 1120-540001-00 FUSE HOLDER 1115-520013-00 LED INDICATOR 0000-000109-00...
  • Page 112: Wiring Harness (Mono)

    R6831 Figure 12-24 Wiring Harness (Mono) INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-500010-00 FUSE, 10A 2108-520001-00 HARNESS, MAIN 12-42 BG-S22-0812...
  • Page 113: Wiring Harness (Telescopic)

    R6868 Figure 12-25 Wiring Harness (Telescopic) INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1120-500010-00 FUSE, 10A 2108-520001-60 HARNESS, MAIN BG-S22-0812 12-43...
  • Page 114: Wiring Cables (Mono)

    R6869 Figure 12-26 Wiring Cables (Mono) INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1115-231000-00 BRACKET 2108-530006-00 CABLE P- 0000-000004-00 • SCREW, M5 X 12 2108-530005-00 CABLE P+ 0000-000108-00 • NUT, M6 2108-530009-00 CABLE C3 0000-000056-00 • WASHER, LOCK, M6 2108-530010-00 CABLE C4 0000-000380-00...
  • Page 115: Wiring Cables (Telescopic)

    R6870 Figure 12-27 Wiring Cables (Telescopic) INDEX PART INDEX PART PART NAME REQD. PART NAME REQD. 1115-231000-00 BRACKET 2108-530006-60 CABLE P- 0000-000004-00 • SCREW, M5 X 12 2108-530005-60 CABLE P+ 0000-000108-00 • NUT, M6 2108-530009-60 CABLE C3 0000-000056-00 • WASHER, LOCK, M6 2108-530010-60 CABLE C4 0000-000380-00...
  • Page 116 12-46 BG-S22-0812...
  • Page 118 Corporate 85 Heart Lake Road South USA 6350 Burnt Poplar Road Brampton, ON, Canada L6W 3K2 Greensboro, NC 27409 t 905.457.3900 f 905.457.2313 www.BlueGiant.com If calling within North America: t 1.800.668.7078 f 1.888.378.5781 © Copyright Blue Giant Equipment Corporation 2014...

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