Big Joe M22 Installation, Operation, Maintenance & Repair Parts
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Big Joe M22 Installation, Operation, Maintenance & Repair Parts

Big Joe M22 Installation, Operation, Maintenance & Repair Parts

Manually propelled, semi-electric lift truck
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M22
MANUALLY PROPELLED,
SEMI-ELECTRIC LIFT TRUCK
Used from Serial Number 326100281
Operation
Maintenance
Repair Parts List
Big Lift LLC
MANUAL NO. BL-M22EP-0119 - 01-11-2019
www.bigjoeforklifts.com

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  • Page 1 MANUALLY PROPELLED, SEMI-ELECTRIC LIFT TRUCK Used from Serial Number 326100281 Operation Maintenance Repair Parts List Big Lift LLC MANUAL NO. BL-M22EP-0119 - 01-11-2019 www.bigjoeforklifts.com...
  • Page 2 WARNING Do not operate this truck unless you have been autho- Use special care when operating on ramps travel rized and trained to do so, and have read all warnings slowly, and do not angle or turn. Travel with load and instructions in Operator’s Manual and on this downhill.
  • Page 3 TABLE OF CONTENTS Section Page Section Page DESCRIPTION ............1-1 LIFT SYSTEM SERVICING ........5-1 1-1 INTRODUCTION ..........1-1 5-1 GENERAL ............5-1 1-2 GENERAL DESCRIPTION .........1-1 5-2 LIFT CHAIN WEAR INSPECTION..... 5-1 1-3 SAFETY FEATURES..........1-1 5-3 LIFT CHAINS ADJUSTMENT ......5-1 5-4 LIFT CHAINS REPLACEMENT ......
  • Page 4 NOTES BL-M22EP-0119 - 01-11-2019...
  • Page 5 SECTION 1 DESCRIPTION 1-1. INTRODUCTION. This publication describes the 12 volt M22 lift truck distributed by Big Lift LLC. Included are operating instructions, planned maintenance instructions, lubri- cation procedures, corrective maintenance procedures and a complete parts list with part location illustrations.
  • Page 6 R3851 Figure 1-2. M22 Lift Truck Pos. # Description Pos. # Description Handle Frame / Mast Battery Charger Cord Lift Cylinder Pump and Motor Assembly Lift / Lower Lever Cover Battery Discharge Indicator (BDI) Foot Actuated Floor Lock Emergency Stop Switch...
  • Page 7 2-2. OPERATING PRECAUTIONS. Table 2-1 covers important inspection points on the M22 lift truck which should be checked prior to opera- WARNING: Improper operation of the lift truck may tion. Depending on use some trucks may require addi- result in operator injury, or load and/or lift tional checks.
  • Page 8 Table 2-1 Operator Checks ITEM PROCEDURE Hydraulic System Check for signs of fluid leakage. Forks Check for cracks and damage and that they are properly secured. Chains, cables and hoses Check that they are in place, properly secured and not damaged. Guards Check that safety guards are in place, properly secured and not damaged.
  • Page 9 The operator handle located on the mast is used to propel and steer the lift truck. R8355 R8356 R8354 Figure 2-3. M22 Lift Truck 2-5. TRANSPORT. Apply pressure to the operator handle to move the truck forward. Lower the operator handle so 2-5.1. Moving, Positioning and Stopping that you are further away from the truck and move the truck in reverse.
  • Page 10 2-5.2. Turning Move the lift truck into position so that the forks are centered under the load. Release the floor lock. Move the lift truck forward to place the load as far NOTE: Turning and maneuvering the lift truck is back as possible toward the lift carriage.
  • Page 11 SECTION 3 PLANNED MAINTENANCE 3-1. GENERAL. 3-3. BATTERY CARE. Planned maintenance consists of periodic visual and 3-3.1. General operational checks, parts inspection, lubrication, and The care and maintenance of the battery is very scheduled maintenance designed to prevent or dis- important to obtain efficient truck operation and maxi- cover malfunctions and defective parts.
  • Page 12 3-3.2. Safety Rules Check the condition of the AC cord and battery cables. If there are any cuts in the cable, any • Do not lay metallic or conductive objects on battery. exposed wires, loose plugs or connectors, DO Arcing will result. NOT attempt to charge the batteries.
  • Page 13 R8357 Figure 3-1 Lubrication Diagram Table 3-3 Lubrication Chart Table 3-4 FIG 3-2 LOCATION METHOD OF TYPE APPLICATION INDEX APPLICATION (Table 3-3) LUBRICANT Lift Carriage Brush No. 1 Light coating where forks slide Mast Brush No. 1 Full length of channel where rollers operate.
  • Page 14 NOTES BL-M22EP-0119 - 01-11-2019...
  • Page 15 SECTION 4 TROUBLESHOOTING 4-1. GENERAL This section gives fixes for some common problems lists these malfunctions, their causes, probable and that may arise while operating the lift truck. Table 4-1 corrective action that will resolve the problem. Table 4-1 Troubleshooting Chart MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION...
  • Page 16 NOTES BL-M22EP-0119 - 01-11-2019...
  • Page 17 SECTION 5 LIFT SYSTEM SERVICING 5-1. GENERAL WARNING: Before attempting any adjustment, make certain power is disconnected. This section covers maintenance and repair proce- dures for the lift system. The lift system consists of: Take up slack in both chains by turning the bottom nuts on adjusting bolts.
  • Page 18 DY_0013 Figure 5-1. Lift Chain BL-M22EP-0119 - 01-11-2019...
  • Page 19 5-5. FORKS. Lift the fork and position the fork at the open slot in the bottom and center of the fork carriage. Check the forks periodically for cracks and other dam- Pull up the fork pin and slide the fork to the age.
  • Page 20 5-7. LIFT CYLINDER (SINGLE STAGE). Remove connector and packing washer from cyl- inder. 5-7.1. Removal Lift chain from sheave and set it aside. Chock all wheels and engage the floor lock. Lift ram head from cylinder. Raise the forks approximately three feet from the 10.
  • Page 21 5-8. LIFT CYLINDER (TELESCOPIC). Remove connector and packing washer from cyl- inder. 5-8.1. Removal Remove bolt, lock washer and flat washer, secur- Chock all wheels and engage the floor lock. ing the lift cylinder to the frame. Raise the forks approximately three feet from the 10.
  • Page 22 NOTES BL-M22EP-0119 - 01-11-2019...
  • Page 23 SECTION 6 HYDRAULIC SYSTEM SERVICING 6-1. HYDRAULIC PUMP ASSEMBLY. Label, then disconnect cables and wires from pump assembly. 6-1.1. Removal Remove two bolts, lock washers and flat washers. Lower pump assembly out of the truck. WARNING: Before disconnecting any hydraulic line, make sure the forks are lowered com- 6-1.2.
  • Page 24 6-2. LIFT CYLINDER. NOTE: Removal procedures are covered in SEC- TION CAUTION: Use the proper tube pipe clamp vise in the following steps to prevent damage to the lift cylinder. Secure the lift cylinder in the vise and remove gland nut. Remove dust seal and O-ring from gland nut.
  • Page 25 ELECTRICAL SYSTEM SERVICING 7-1. HYDRAULIC PUMP MOTOR. 7-2. BATTERY CHARGER. The hydraulic pump motor is part of the hydraulic Your M22 lift truck is supplied with a built in battery pump assembly. Refer to SECTION 6 for removal and charger which makes it a complete, self-contained disassembly.
  • Page 26 NOTES BL-M22EP-0119 - 01-11-2019...
  • Page 27 SECTION 8 FRAME AND RELATED PARTS SERVICING 8-1. GENERAL. Chock the load wheels. Raise the rear of the lift truck with a suitable jack This section covers load wheels, casters and floor lock or another lift truck. Place strong supports approx- replacement.
  • Page 28 Figure 8-1 Frame BL-M22EP-0119 - 01-11-2019...
  • Page 29 SECTION 9 ILLUSTRATED PARTS BREAKDOWN Following is an illustrated parts breakdown of assemblies and parts associated with the M22 Lift Truck starting from Serial Number 326100281. BL-M22EP-0119 - 01-11-2019...
  • Page 30 DY_0001 Figure 9-1 Frame BL-M22EP-0119 - 01-11-2019...
  • Page 31 FRAME Qty. Pos. Part Number Description Notes Reqd. 2010-110000-1A FRAME For Telescopic Mast 2010-110000-2A FRAME For Single stage Mast 2010-150000-10 HAND RAIL 2010-100008-10 SCREW 2010-100002-1A FIXED BLOCK 2010-141000-10 SHAFT 0000-000090-00 SCREW M6×12 2125-101003-00 WASHER 0000-000424-00 BEARING 2010-140001-10 LOAD WHEEL 2010-130000-10 STRADDLE LEG R 2010-120000-10 STRADDLE LEG L...
  • Page 32 DY_0002 Figure 9-2 Caster Assembly BL-M22EP-0119 - 01-11-2019...
  • Page 33 CASTER ASSEMBLY Qty. Pos. Part Number Description Notes Reqd. There are two Caster 2010-130000-00 CASTER ASSEMBLY Assemblies on the truck. 2010-131000-00 WHEEL BRACKET 2010-120001-00 SHAFT 0000-000077-00 SCREW M6×12 0000-000056-00 LOCK WASHER Ø6 0000-000437-00 FLAT WASHER Ø6 0000-000019-00 BEARING 2010-120003-00 NYLON WHEEL 2010-122000-00 PLATE 0000-000380-00...
  • Page 34 DY_0006 Figure 9-3 Elevation System - Single Stage BL-M22EP-0119 - 01-11-2019...
  • Page 35 ELEVATION SYSTEM - SINGLE STAGE Qty. Pos. Part Number Description Notes Reqd. 0000-000756-00 RETAINER RING Ø40 2108-600001-00 SHAFT 2108-600003-00 WASHER 2108-600002-00 CHAIN ROLLER 2108-620000-00 CHAIN BRACKET 0000-000374-00 SCREW M12×30 0000-000060-00 LOCK WASHER Ø12 0000-000373-00 FLAT WASHER Ø12 0000-000321-00 SCREW M8×20 2111-600001-20 CYLINDER BRACKET 2108-410000-60...
  • Page 36 DY_0007 Figure 9-4 Lift Cylinder - Single Stage BL-M22EP-0119 - 01-11-2019...
  • Page 37 LIFT CYLINDER - SINGLE STAGE Qty. Pos. Part Number Description Notes Reqd. 2108-410000-60 LIFT CYLINDER Lift Height 62” (1575mm) 2110-2BG SEAL KIT FOR CYLINDER Includes Pos. # 8, 9, 11 2125-410001-00 PISTON ROD 2125-410002-00 PISTON 2125-410003-00 COLLAR 2125-410006-00 BUSHING 2108-411000-60 CYLINDER 2125-410004-0A 0000-000084-00...
  • Page 38 DY_0008 Figure 9-5 Fork Carriage - Single Stage 9-10 BL-M22EP-0119 - 01-11-2019...
  • Page 39 FORK CARRIAGE - SINGLE STAGE Qty. Pos. Part Number Description Notes Reqd. 0000-000284-00 BOLT M12×30 0000-000060-00 LOCK WASHER Ø12 0000-000373-00 FLAT WASHER Ø12 2125-632000-00 BLOCKING SHELF 2010-631000-20 FORK FRAME 2108-632000-70 ROLLER ASSEMBLY Incl. Pos. # 9-13 2108-630001-10 FORK 2125-630001-10 FORK PIN KIT 0000-001525-00 SCREW M12×10 0000-000761-00...
  • Page 40 DY_0009 Figure 9-6 Mast Chain Assembly - Single Stage 9-12 BL-M22EP-0119 - 01-11-2019...
  • Page 41 MAST CHAIN ASSEMBLY - SINGLE STAGE Qty. Pos. Part Number Description Notes Reqd. 2108-640004-00 CHAIN Lift Height 62” (1575mm) 2108-640001-00 BOLT 0000-000237-00 NUT M16×1.5 2108-640002-00 PIN SHAFT 0000-000188-00 PIN Ø3.2×20 2108-640003-00 CHAIN ANCHOR 0000-000176-00 FLAT WASHER Ø8 BL-M22EP-0119 - 01-11-2019 9-13...
  • Page 42 DY_0010 Figure 9-7 Elevation System - Telescopic 9-14 BL-M22EP-0119 - 01-11-2019...
  • Page 43 ELEVATION SYSTEM - TELESCOPIC Qty. Pos. Part Number Description Notes Reqd. 0000-000761-00 SCREW M12×20 2108-600002-60 BOLT 0000-000757-00 NUT M20X1.5 2108-600003-60 SPRING 2108-600004-60 POSITIONING ROD 2108-600005-60 CHAIN ROLLER Ø84 / Ø52X33 0000-000100-00 BEARING 0000-000294-00 RETAINER RING Ø25 ELASTIC COLLAR Φ52 0000-000758-00 0000-000374-00 SCREW M12×30 0000-000060-00...
  • Page 44 DY_0011 Figure 9-8 Lift Cylinder - Telescopic 9-16 BL-M22EP-0119 - 01-11-2019...
  • Page 45 LIFT CYLINDER - TELESCOPIC Qty. Pos. Part Number Description Notes Reqd. 2108-410000-60-04 LIFT CYLINDER Lift Height 96” (2440mm) 2108-410000-60-02 LIFT CYLINDER Lift Height 116” (2945mm) 2110-2BG SEAL KIT FOR CYLINDER Includes Pos. # 8, 9, 11 2125-410001-00-01 PISTON ROD Lift Height 96” (2440mm) 2125-410001-00-03 PISTON ROD Lift Height 116”...
  • Page 46 DY_0012 Figure 9-9 Fork Carriage - Telescopic 9-18 BL-M22EP-0119 - 01-11-2019...
  • Page 47 FORK CARRIAGE - TELESCOPIC Qty. Pos. Part Number Description Notes Reqd. 0000-000284-00 BOLT M12×30 0000-000060-00 LOCK WASHER Ø12 0000-000373-00 FLAT WASHER Ø12 2125-632000-00 LOAD BACKREST 2111-631000-10 FORK FRAME 2108-632000-70 ROLLER ASSEMBLY Incl. Pos. # 9-13 2108-630001-10 FORK 2125-630001-10 FORK PIN KIT 0000-001525-00 SCREW M12×10 0000-000761-00...
  • Page 48 DY_0013 Figure 9-10 Mast Chain Assembly - Telescopic 9-20 BL-M22EP-0119 - 01-11-2019...
  • Page 49 MAST CHAIN ASSEMBLY - TELESCOPIC Qty. Pos. Part Number Description Notes Reqd. 2108-640001-60-04 CHAIN Lift Height 96” (2440mm) 2108-640001-60-02 CHAIN Lift Height 116” (2945mm) 2108-640002-60 BOLT 0000-000237-00 NUT M16×1.5 0000-000220-00 WASHER Ø16 0000-000188-00 PIN Ø3.2×20 0000-000779-00 PIN Ø6×30 BL-M22EP-0119 - 01-11-2019 9-21...
  • Page 50 DY_0003 Figure 9-11 Hydraulic System 9-22 BL-M22EP-0119 - 01-11-2019...
  • Page 51 HYDRAULIC SYSTEM Qty. Pos. Part Number Description Notes Reqd. 2010-450000-00 HYDRAULIC PUMP ASSEMBLY 3218-330006-00 LIFT KNOB 2010-100009-10 HANDLE SHEATH 0000-000109-00 SCREW M8×16 0000-000159-00 LOCK WASHER Ø8 0000-000176-00 FLAT WASHER Ø8 2010-432000-00 OIL PIPE 2702-381600-00 CONNECTOR G3/8-M16×1.5 0000-000634-00 WASHER Ø18 2108-400002-00 OIL RETURN PIPE 0000-000472-00 CLIP...
  • Page 52 DY_0015 Figure 9-12 HYDRAULIC PUMP & MOTOR ASSEMBLY 9-24 BL-M22EP-0119 - 01-11-2019...
  • Page 53 HYDRAULIC PUMP & MOTOR ASSEMBLY Qty. Pos. Part Number Description Notes Reqd. 2010-450001-00 SAFE VALVE 2010-450002-00 SWITCH 2010-450003-00 MOTOR 2010-450004-00 COUPLING 2010-450005-00 O-RING 2010-451001-00 SWITCH 2010-451002-00 STAND 2010-451003-00 MANUAL VALVE 2010-451004-00 BALANCE VALVE 2010-450006-00 PLUG 2010-450007-00 CHECK VALVE 2010-450008-00 SEALING PAD 2010-450009-00 PUMP FRAME 2010-450010-00...
  • Page 54 DY_0004 Figure 9-13 Electrical System 9-26 BL-M22EP-0119 - 01-11-2019...
  • Page 55 ELECTRICAL SYSTEM Qty. Pos. Part Number Description Notes Reqd. 2010-500002-00 INDICATOR ,WITH HOUR METER 1220-520007-0D METER WIRE HARNESS 0000-000004-00 SCREW M5×12 0000-000206-00 LOCK WASHER Ø5 1114-540000-00 EMERGENCY STOP SWITCH 1114-540001-00 SWITCH BUTTON 1114-540002-00 EMERGENCY STOP SWITCH SEAT 2010-520000-00 CHARGER ASSEMBLY,15A/12V 1115-500006-10 CHARGER CABLE 0000-000055-00...
  • Page 56 DY_0005 Figure 9-14 Wiring Cables 9-28 BL-M22EP-0119 - 01-11-2019...
  • Page 57 WIRING CABLES Qty. Pos. Part Number Description Notes Reqd. 2010-530001-00 POSITIVE CABLE 2010-530002-00 P+ CABLE 2010-530003-00 NEGATIVE CABLE 1118-560007-00 BATTERY 100Ah BL-M22EP-0119 - 01-11-2019 9-29...
  • Page 58 Big Lift LLC...

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